Hydrogen energy systems

ABSTRACT

Hydrogen energy systems for obtaining hydrogen gas from a solid storage medium using controlled lasers. Also disclosed are systems for charging/recharging magnesium with hydrogen to obtain magnesium hydride. Other relatively safe systems assisting storage, transport and use (as in vehicles) of such solid storage mediums are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part and is related to andclaims priority from non-provisional patent application Ser. No.13/397,611, filed Feb. 15, 2012 entitled “HYDROGEN ENERGY SYSTEMS”,which is related to and claims priority from prior provisionalapplication Ser. No. 61/443,599, filed Feb. 16, 2011, entitled “HYDROGENENERGY SYSTEMS” and which is additionally a continuation-in-part and isrelated to and claims priority from non-provisional patent applicationSer. No. 12/684,420, filed Jan. 8, 2010, entitled “HYDROGEN ENERGYSYSTEMS”, which is related to and claims priority from prior provisionalapplication Ser. No. 61/160,608, filed Mar. 16, 2009, entitled “HYDROGENENERGY SYSTEMS”; and which is also related to and claims priority fromprior provisional application Ser. No. 61/143,272, filed Jan. 8, 2009,entitled “HYDROGEN ENERGY SYSTEMS”; and which is further related toInternational Patent Application No. PCT/US2008/076900, filed Sep. 18,2008, entitled “HYDROGEN ENERGY SYSTEMS”; and which is moreover isrelated to Canadian National Stage Patent Application No. 2,737,518,filed Mar. 16, 2011, entitled “HYDROGEN ENERGY SYSTEMS”; and which iseven further related to European Regional Stage Patent Application No.08 831 749.0, filed Apr. 19, 2010, entitled “HYDROGEN ENERGY SYSTEMS”;and which is additionally a continuation-in-part and is related to andclaims priority from non-provisional patent application Ser. No.12/212,571, filed Sep. 17, 2008, entitled “HYDROGEN ENERGY SYSTEMS”,which claims priority to related prior provisional application Ser. No.60/973,369, filed Sep. 18, 2007, entitled “HYDROGEN ENERGY SYSTEMS”,prior provisional application Ser. No. 61/022,572, filed Jan. 22, 2008,entitled “HYDROGEN ENERGY SYSTEMS”, and prior provisional applicationSer. No. 61/024,856, filed Jan. 30, 2008, entitled “HYDROGEN ENERGYSYSTEMS”; and this application is also related to and claims priorityfrom prior provisional application Ser. No. 61/675,295, filed Jul. 24,2012, entitled “HYDROGEN ENERGY SYSTEMS”; and this application isfurther related to International Patent Application No.PCT/US2010/027548, filed Mar. 16, 2010, entitled “HYDROGEN ENERGYSYSTEMS”; and this application moreover is related to Korean NationalStage Patent Application No. 10-2011-7024393, filed Oct. 17, 2011,entitled “HYDROGEN ENERGY SYSTEMS”; and this application additionally isrelated to Japanese National Stage Patent Application No. 2012-500908,filed Sep. 16, 2011, entitled “HYDROGEN ENERGY SYSTEMS”; and which iseven further related to European Regional Stage Patent Application No.10 754 015.5, filed Oct. 14, 2011, entitled “HYDROGEN ENERGY SYSTEMS”;and this application is further related to International PatentApplication No. PCT/US2012/25466, filed Feb. 16, 2012, entitled“HYDROGEN ENERGY SYSTEMS”; the contents of all of which are incorporatedherein by this reference and are not admitted to be prior art withrespect to the present invention by the mention in this cross-referencesection.

BACKGROUND

This invention relates to providing hydrogen energy systems. Moreparticularly, this invention relates to providing hydrogen energysystems using magnesium hydride for hydrogen storage. Even moreparticularly, this invention relates to such hydrogen energy systemsusing laser excitation to assist adsorption of hydrogen gas from themagnesium hydride.

In using hydrogen energy systems, it is difficult to safely storehydrogen gas for use in providing energy for systems, such as vehicles,given the highly combustible nature of hydrogen. While hydrogen has ahigh energy to weight ratio, storage of hydrogen in a gaseous state(even compressed) yields a low energy to volume ratio making suchstorage impractical, particularly for mobile use. Thus, it would beuseful to provide safe and compact storage of hydrogen energy near alocation where hydrogen gas will be used for energy purposes.

OBJECTS AND FEATURES OF THE INVENTION

A primary object and feature of the present invention is to provide asystem overcoming the above-mentioned problem.

It is a further object and feature of the present invention to providesuch a hydrogen energy system wherein such magnesium hydride may besafely stored.

Another object and feature of the present invention is to provide suchmagnesium hydride in the form of a “disk” resembling a CD.

Yet another object and feature of the present invention is to provide alaser system to cooperate with the magnesium hydride disk to providerelease of hydrogen gas therefrom.

A further object and feature of the present invention is to provide alaser system utilizing an array of lasers to cooperate with themagnesium hydride disk to provide release of hydrogen gas therefrom.

Yet another object and feature of the present invention is to providecontrolled coherent light energy to successive portions of a surface ofsuch magnesium hydride disk to provide controlled release of hydrogengas.

A further object and feature of the present invention is to provide asystem for recharging such disks with hydrogen after such controlledrelease of hydrogen gas.

Another object and feature of the present invention is to providehydrogen energy for at least one vehicle, preferably an automobile, inthe form of hydrogen gas controllably released from such storage inmagnesium hydride disks.

Another primary object and feature of the present invention is toprovide a system of manufacturing magnesium hydride disks, which disksmay releasably store hydrogen within a compact volume.

A further object and feature of the present invention is to provide asystem of manufacturing magnesium hydride disks, which disks areperforated to expose a large surface area of interaction and mayreleasably store hydrogen within a compact volume.

A further primary object and feature of the present invention is toprovide such hydrogen energy systems that are efficient, inexpensive,and handy. Other objects and features of this invention will becomeapparent with reference to the following descriptions.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment hereof, this inventionprovides a hydrogen energy method comprising the steps of: using atleast one material deposition apparatus structured and arranged tomanufacture at least one hydrogen storer; and manufacturing such atleast one hydrogen storer structured and arranged to store at least onesubstantial amount of hydrogen; wherein such at least one hydrogenstorer comprises at least one hydrogen-release permitter structured andarranged to permit photonic-excitation-assisted release of storedhydrogen from such at least one hydrogen storer; and providing such atleast one hydrogen storer to assist at least one commercial use ofhydrogen gas. Moreover, it provides such a hydrogen energy methodwherein the step of using at least one material deposition apparatuscomprises the step of using at least one filtered cathodic arcdeposition apparatus. Additionally, it provides such a hydrogen energymethod wherein the step of manufacturing such at least one hydrogenstorer comprises the step of forming at least one layer of hydrogenstorer material. Also, it provides such a hydrogen energy method whereinsuch hydrogen storer material comprises magnesium.

In addition, it provides such a hydrogen energy method wherein suchhydrogen storer material comprises magnesium hydride. And, it providessuch a hydrogen energy method wherein the step of manufacturing such atleast one hydrogen storer further comprises the step of formingalternating layers comprising such at least one layer of hydrogen storermaterial and at least one layer of Nitinol. Further, it provides such ahydrogen energy method wherein such hydrogen storer material comprisesmagnesium. Even further, it provides such a hydrogen energy methodwherein such hydrogen storer material comprises magnesium hydride.Moreover, it provides such a hydrogen energy method wherein the step offorming at least one layer of hydrogen storer material comprises thestep of deposition of such hydrogen storer material on at least onesubstrate structured and arranged to receive deposition of such hydrogenstorer material. Additionally, it provides such a hydrogen energy methodwherein such at least one substrate comprises stainless steel. Also, itprovides such a hydrogen energy method wherein such hydrogen storermaterial comprises magnesium. In addition, it provides such a hydrogenenergy method wherein such at least one substrate comprises Nitinol.

And, it provides such a hydrogen energy method wherein such hydrogenstorer material comprises magnesium hydride. Further, it provides such ahydrogen energy method wherein such at least one hydrogen storercomprises a thickness greater than about 15 microns. Even further, itprovides such a hydrogen energy method wherein such at least onehydrogen storer comprises a thickness between about 15 microns and about30 microns. Moreover, it provides such a hydrogen energy method of Claim1 further comprising the step of forming at least one pattern ofcavities structured and arranged to provide substantially uniformporosity. Additionally, it provides such a hydrogen energy methodwherein such at least one pattern of cavities comprises at least oneangle, with respect to at least one surface of hydrogen storer material,of about 45°. Also, it provides such a system wherein each of suchcavities comprises a diameter of about 50 μm. In addition, it providessuch a hydrogen energy method wherein the step of forming at least onelayer of hydrogen storer material comprise the step of creating at leastone magnetic field encompassing such hydrogen storer material duringformation of such at least one layer. And, it provides such a hydrogenenergy method wherein the step of manufacturing such at least onehydrogen storer comprises the step of forming such at least one hydrogenstorer as a disk.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one hydrogen-release permitter structured and arranged to permitphotonic-excitation-assisted release of stored hydrogen from such atleast one hydrogen storer, and a unified matrix of granules in amaterial structured and arranged to cyclically store hydrogen andrelease stored hydrogen; and wherein controlled storage and release ofhydrogen is achieved to assist at least one commercial use. Further, itprovides such a hydrogen energy system wherein such a unified matrix ofgranules comprises grain sizes less than about 300 nm. Even further, itprovides such a hydrogen energy system wherein such a unified matrix ofgranules comprises grain sizes less than about 150 nm.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one hydrogen-release permitter structured and arranged to permitphotonic-excitation-assisted release of stored hydrogen from such atleast one hydrogen storer, and a unified matrix of granules in amaterial structured and arranged to cyclically store hydrogen andrelease stored hydrogen; and at least one photonic exciter structuredand arranged to photonically excite such at least one hydrogen storer toassist release of such stored hydrogen from such at least one hydrogenstorer; wherein such at least one photonic exciter comprises at leastone controller structured and arranged to control suchphotonic-excitation-assisted release of hydrogen; and wherein controlledstorage and release of hydrogen is achieved to assist at least onecommercial use.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one hydrogen-release permitter structured and arranged to permitphotonic-excitation-assisted release of stored hydrogen from such atleast one hydrogen storer; and at least one photonic exciter structuredand arranged to photonically excite such at least one hydrogen storer toassist release of such stored hydrogen from such at least one hydrogenstorer; wherein such at least one photonic exciter comprises at leastone controller structured and arranged to control suchphotonic-excitation-assisted release of hydrogen gas so as to assist atleast one commercial use. Moreover, it provides such a hydrogen energysystem wherein such at least one hydrogen-release permitter comprises atleast one plasmonic-effect-capable dielectric structured and arranged topermit creation of surface plasmon polaritons. Additionally, it providessuch a hydrogen energy system wherein such at least oneplasmonic-effect-capable dielectric comprises at least one super-elasticmaterial layer structured and arranged to permit resilience throughmultiple absorption-desorption cycles. Also, it provides such a hydrogenenergy system wherein such at least one photonic exciter comprises atleast one array of lasers. In addition, it provides such a hydrogenenergy system wherein such at least one plasmonic-effect-capabledielectric comprises at least Nitinol and magnesium.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one metal surfaceportion capable of absorbing hydrogen; at least one supply of hydrogengas; and at least one electromagnetic field generator structured andarranged to generate at least one electromagnetic field sufficient toform at least one supply of hydrogen plasma; wherein such at least oneelectromagnetic field generator is located in at least one position suchthat such at least one supply of hydrogen plasma is located in at leastone second position; and at least one metal surface locator structuredand arranged to locate such at least one metal surface portion withinsuch at least one second position; wherein such at least one metalsurface portion may absorb hydrogen to form at least one metal hydridesurface portion. And, it provides such a hydrogen energy system whereinsuch at least one metal surface portion comprises at least oneplasmonic-effect-capable dielectric structured and arranged to permitcreation of surface plasmon polaritons. Further, it provides such ahydrogen energy system wherein such at least oneplasmonic-effect-capable dielectric comprises at least one super-elasticmaterial layer structured and arranged to permit resilience throughmultiple absorption-desorption cycles. Even further, it provides such ahydrogen energy system wherein such at least oneplasmonic-effect-capable dielectric comprises at least Nitinol andmagnesium. Moreover, it provides such a system according to Claim 7wherein such at least one metal surface portion comprises at least onepattern of cavities structured and arranged to provide substantiallyuniform porosity. Additionally, it provides such a system wherein suchat least one pattern of cavities comprises at least one angle, withrespect to such at least one metal surface portion, of about 45°. Also,it provides such a system wherein each of such cavities comprises adiameter of about 50 μm. In addition, it provides such a system whereinsuch at least one metal surface portion comprises magnesium hydride.

In accordance with another preferred embodiment hereof, this inventionprovides a method, relating to manufacturing at least one hydrogenstorer, comprising the steps of: vapor depositing at least one hydrogenstorer material adapted to store hydrogen onto at least one substrate;wherein such at least one hydrogen storer material and such at least onesubstrate comprise at least one plasmonic-effect-capable dielectricstructured and arranged to permit creation of surface plasmonpolaritons; cutting such at least one hydrogen storer material into atleast one geometric shape; and perforating such at least one hydrogenstorer material; wherein such method produces at least one hydrogenstorer. And, it provides such a method wherein such at least onegeometric shape comprises at least one disk. Further, it provides such amethod wherein the step of perforating comprises the step of drilling atleast one hole. Even further, it provides such a method wherein the stepdrilling comprises at least one laser. Even further, it provides such amethod wherein such at least one chemical comprises HCl. Even further,it provides such a method wherein such at least one substrate comprisesat least one super-elastic material structured and arranged to permitresilience through multiple absorption-desorption cycles. Even further,it provides such a method wherein such at least one hydrogen storermaterial comprises magnesium.

In accordance with another preferred embodiment hereof, this inventionprovides a process, relating to controlled commercial use of hydrogengas, comprising the steps of: providing at least one supply of hydrogengas; and providing at least one electromagnetic field sufficient to format least one supply of hydrogen plasma; wherein such at least one supplyof hydrogen plasma is formed adjacent to at least one metal surfaceportion capable of storing hydrogen; and wherein such at least one metalsurface portion absorbs hydrogen from such at least one supply ofhydrogen plasma to form at least one metal hydride; and providing atleast one hydrogen storer structured and arranged to store, using suchat least one metal hydride, at least one substantial amount of hydrogenso as to permit photonic-excitation-assisted release of stored hydrogen;using at least one photonic exciter to photonically excite such at leastone hydrogen storer to assist release of such stored hydrogen ashydrogen gas; and controlling such photonic-excitation-assisted releaseof such hydrogen gas so as to assist at least one commercial use.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one hydrogen-release permitter structured and arranged to permitphotonic-excitation-assisted release of stored hydrogen from such atleast one hydrogen storer; and at least one photonic exciter structuredand arranged to photonically excite such at least one hydrogen storer toassist release of such stored hydrogen from such at least one hydrogenstorer; wherein such at least one photonic exciter comprises at leastone controller structured and arranged to control suchphotonic-excitation-assisted release of hydrogen gas so as to assist atleast one commercial use.

In accordance with a preferred embodiment hereof, this invention alsoprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one hydrogen-release permitter structured and arranged to permitphotonic-excitation-assisted release of stored hydrogen from such atleast one hydrogen storer; and at least one photonic exciter structuredand arranged to photonically excite such at least one hydrogen storer toassist release of the stored hydrogen from such at least one hydrogenstorer; wherein such at least one photonic exciter comprises at leastone controller structured and arranged to controlphotonic-excitation-assisted release of hydrogen; and at least onehydrogen collector structured and arranged to assist collection ofreleased hydrogen; wherein hydrogen may be stored in such at least onehydrogen storer until controllably released to permit use as desired.

Moreover, it provides such a hydrogen energy system wherein such atleast one photonic exciter comprises at least one wavelength of lightbetween about 530 nm and about 1700 nm. Additionally, it provides such ahydrogen energy system wherein such at least one photonic excitercomprises at least one wavelength of light of about 784 nm. Also, itprovides such a hydrogen energy system wherein such at least onephotonic exciter comprises at least one power between about 200 mW andabout 2000 mW. In addition, it provides such a hydrogen energy systemwherein such at least one photonic exciter comprises at least one powerof about 200 mW.

And, it provides such a hydrogen energy system wherein such at least onehydrogen collector comprises at least one negative pressure environment.Further, it provides such a hydrogen energy system wherein such at leastone negative pressure environment comprises at least one pressurebetween about negative one millimeter of mercury and about negative twoatmospheres. Even further, it provides such a hydrogen energy systemwherein such at least one negative pressure environment comprises atleast one pressure of about negative one atmosphere.

Moreover, it provides such a hydrogen energy system wherein such atleast one photonic exciter comprises at least one beam of light with atleast one radius of between about 10 nm and about 2 mm. Additionally, itprovides such a hydrogen energy system wherein such at least onephotonic exciter comprises at least one beam of light with at least oneradius of about 15 nm. Also, it provides such a hydrogen energy systemwherein such at least one photonic exciter is structured and arranged toexcite at least one portion of such at least one hydrogen storer toinduce at least one temperature between about 280° C. and about 390° C.in such at least one portion. In addition, it provides such a hydrogenenergy system wherein such at least one hydrogen storer comprises atleast one hydride.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one metal surfaceportion capable of absorbing hydrogen; at least one supply of hydrogengas; and at least one electromagnetic field generator structured andarranged to generate at least one electromagnetic field sufficient toform at least one supply of hydrogen plasma; wherein such at least oneelectromagnetic field generator is located in at least one position suchthat such at least one supply of hydrogen plasma is located in at leastone second position; and at least one metal surface locator structuredand arranged to locate such at least one metal surface portion withinsuch at least one second position; wherein such at least one metalsurface portion may absorb hydrogen to form at least one metal hydridesurface portion.

And, it provides such a hydrogen energy system wherein such at least oneelectromagnetic field generator comprises: at least one microwave fieldgenerator; and at least one radio wave field generator. Further, itprovides such a hydrogen energy system wherein such at least onemicrowave field generator comprises at least two microwave fieldgenerators.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer comprising at least one disk structured and arranged to store atleast one substantial amount of hydrogen; wherein such at least onehydrogen storer comprises at least one central spin axis locatorstructured and arranged to locate at least one central spin axis of suchat least one disk; and wherein such at least one disk may rotate aboutsuch at least one central spin axis of such at least one disk; andwherein such at least one disk comprises at least one spinner motorgripper capable of being gripped by at least one motor driven spinner;wherein such at least one spinner motor gripper is substantiallyconcentric to such at least one central spin axis; wherein such at leastone spinner motor gripper is structured and arranged to assist enablingsuch at least one disk to be spun about such at least one central spinaxis of such at least one disk by such at least one motor drivenspinner; and wherein such at least one disk is structured and arrangedto spin substantially stably.

Even further, it provides such a hydrogen energy system wherein such atleast one disk further comprises at least one outer diameter betweenabout 50 mm and about 150 mm. Moreover, it provides such a hydrogenenergy system wherein such at least one disk further comprises at leastone outer diameter of about 120 mm. Additionally, it provides such ahydrogen energy system wherein such at least one central spin axislocator comprises at least one diameter between about 5 mm and about 15mm. Also, it provides such a hydrogen energy system wherein such atleast one central spin axis locator comprises at least one diameter ofabout 15 mm.

In addition, it provides such a hydrogen energy system wherein such atleast one disk comprises at least one hydride disk. And, it providessuch a hydrogen energy system wherein such at least one hydride diskfurther comprises at least one outer diameter between about 50 mm andabout 150 mm. Further, it provides such a hydrogen energy system whereinsuch at least one hydride disk further comprises at least one outerdiameter of about 120 mm. Even further, it provides such a hydrogenenergy system wherein such at least one central spin axis locatorcomprises at least one diameter between about 5 mm and about 15 mm.Moreover, it provides such a hydrogen energy system wherein such atleast one central spin axis locator comprises at least one diameter ofabout 15 mm.

Additionally, it provides such a hydrogen energy system wherein such atleast one hydride disk comprises at least one thickness of about onemillimeter. Also, it provides such a hydrogen energy system wherein suchat least one hydride disk further comprises at least one metal hydride.In addition, it provides such a hydrogen energy system wherein such atleast one hydride disk substantially comprises magnesium hydride. And,it provides such a hydrogen energy system wherein such at least onehydride disk comprises hydrogenated AZ31B.

Further, it provides such a hydrogen energy system wherein such at leastone hydride disk further comprises at least one catalyst structured andarranged to assist hydrogenation of such at least one hydride disk. Evenfurther, it provides such a hydrogen energy system wherein such at leastone catalyst comprises nickel. Moreover, it provides such a hydrogenenergy system wherein such at least one catalyst comprises palladium.Additionally, it provides such a hydrogen energy system wherein such atleast one catalyst comprises titanium. Also, it provides such a hydrogenenergy system wherein such at least one hydride disk comprises surfaceirregularities of less than about two micrometers. In addition, itprovides such a hydrogen energy system further comprising at least onedisk coating comprising at least one optically clear mineral oil.

And, it provides such a hydrogen energy system further comprising: atleast one photonic-exciter structured and arranged to photonicallyexcite such at least one hydrogen storer to assist release of the storedhydrogen from such at least one hydrogen storer; and wherein such atleast one hydrogen storer comprises at least one hydrogen-releasepermitter structured and arranged to permit photonic-excitation-assistedrelease of stored hydrogen from such at least one hydrogen storer; andwherein such at least one photonic-exciter comprises at least onecontroller structured and arranged to controlphotonic-excitation-assisted release of hydrogen; and at least onehydrogen collector structured and arranged to assist collection ofreleased hydrogen; and wherein hydrogen may be stored in such at leastone hydrogen storer until controllably released permitting use asdesired.

Further, it provides such a hydrogen energy system wherein such at leastone disk comprises at least one hydride. The hydrogen energy systemwherein such at least one disk is stored in at least one optically clearmineral oil. Even further, it provides such a hydrogen energy systemwherein such at least one hydrogen collector further comprises at leastone mineral oil condenser structured and arranged to assist collectionof mineral oil vaporized during such photonic-exciter-assisted releaseof hydrogen.

Moreover, it provides such a hydrogen energy system further comprising:at least one hydrogen fuel user structured and arranged to use hydrogenas at least one fuel in at least one vehicle; wherein such at least onehydrogen fuel user comprises at least one energy converter structuredand arranged to assist conversion of collected hydrogen through at leastone energy-conversion process; and wherein such at least oneenergy-conversion process provides energy to operate such at least onevehicle. Additionally, it provides such a hydrogen energy system furthercomprising at least one hydrogen container structured and arranged tocontain at least one volume of hydrogen sufficient to supply increasedfuel demand from such at least one vehicle during acceleration. Also, itprovides such a hydrogen energy system wherein such at least one energyconverter comprises at least one combustion engine.

In addition, it provides such a hydrogen energy system furthercomprising at least one hydrogen container structured and arranged tocontain at least one volume of hydrogen sufficient to supply increasedfuel demand from such at least one vehicle during acceleration. And, itprovides such a hydrogen energy system wherein such at least one energyconverter comprises at least one hydrogen fuel cell.

Further, it provides such a hydrogen energy system further comprising:at least one supply of hydrogen gas; and at least one electromagneticfield generator structured and arranged to generate at least oneelectromagnetic field sufficient to form at least one supply of hydrogenplasma; wherein such at least one electromagnetic field generator islocated in at least one position such that the at least one supply ofhydrogen plasma is located in at least one second position; and whereinsuch at least one hydrogen storer further comprises at least one metalsurface portion capable of absorbing hydrogen; and at least one metalsurface locator structured and arranged to locate such at least onemetal surface portion within such at least one second position; whereinsuch at least one metal surface portion may absorb hydrogen to form atleast one metal hydride surface portion.

Even further, it provides such a hydrogen energy system wherein aplurality of such at least one hydrogen storers locate serially throughsuch at least one second position. Moreover, it provides such a hydrogenenergy system wherein such at least one hydride disk is stored in atleast one optically clear mineral oil. Additionally, it provides such ahydrogen energy system wherein such plurality of such at least onehydrogen storers may remain in such at least one optically clear mineraloil.

In accordance with another preferred embodiment hereof, this inventionprovides a process, relating to use of hydrogen, comprising the stepsof: providing at least one supply of hydrogen gas; and providing atleast one electromagnetic field sufficient to form at least one supplyof hydrogen plasma; wherein such at least one hydrogen plasma is formedadjacent to at least one metal surface portion capable of storinghydrogen; and wherein such at least one metal surface portion may absorbhydrogen from such at least one supply of hydrogen plasma to form atleast one metal hydride.

In accordance with another preferred embodiment hereof, this inventionprovides a process, relating to use of hydrogen, comprising the stepsof: providing at least one hydride disk capable of releasing hydrogenthrough photonically induced heating; removing at least onehydrogen-expended hydride disk from at least one vehicle; replacing suchat least one hydrogen-expended hydride disk with such at least onehydride disk; and disposing of such at least one hydrogen-expendedhydride disk. Also, it provides such a process wherein such step ofdisposing comprises recycling of such at least one hydrogen-expendedhydride disk.

In accordance with another preferred embodiment hereof, this inventionprovides a process, relating to use of hydrogen, comprising the stepsof: providing at least one hydrogen-expended hydride disk capable ofbeing recycled; purging such at least one hydrogen-expended hydride diskof any unreleased hydrogen; and recharging such purged at least onehydrogen-expended hydride disk with hydrogen forming at least onehydride disk capable of releasing hydrogen through photonically inducedheating.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: at least one hydrogenstorer structured and arranged to store at least one substantial amountof hydrogen; wherein such at least one hydrogen storer comprises atleast one substantially full state when such at least one hydrogenstorer stores such at least one substantial amount of hydrogen; whereinsuch at least one hydrogen storer comprises at least one substantiallyempty state when such at least one hydrogen storer stores substantiallyno amount hydrogen; and wherein such at least one hydrogen storercomprises at least one substantial variation between transparency ofsuch at least one substantially full state and transparency of such atleast one substantially empty state; and at least one transparencyvariation detection device structured and arranged to detect such atleast one substantial variation in transparency of such at least onehydrogen storer; at least one transparency variation data collectorstructured and arranged to collect transparency variation data from suchat least one transparency variation detection device; and at least onetransparency variation data processor structured and arranged toevaluate collected transparency variation data; wherein such evaluationresults in at least one value indicative of hydrogen content of suchsystem.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: hydrogen storer means forstoring at least one substantial amount of hydrogen; wherein suchhydrogen storer means comprises hydrogen-release permitter means forpermitting photonic-excitation-assisted release of stored hydrogen fromsuch hydrogen storer means; and photonic-exciter means for photonicallyexciting such hydrogen storer means to assist release of the storedhydrogen from such hydrogen storer means; wherein such photonic-excitermeans comprises controller means for controllingphotonic-excitation-assisted release of hydrogen; and hydrogen collectormeans for assisting collecting released hydrogen; wherein hydrogen maybe stored in such hydrogen storer means until controllably released topermit use as desired.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: metal surface portionmeans for providing at least one metal surface portion capable ofabsorbing hydrogen; hydrogen supply means for providing at least onesupply of hydrogen gas; and electromagnetic field generator means forgenerating at least one electromagnetic field sufficient to form atleast one supply of hydrogen plasma; wherein such electromagnetic fieldgenerator means is located in at least one position such that the atleast one supply of hydrogen plasma is located in at least one secondposition; and metal surface locator means for locating such metalsurface portion means within such at least one second position; whereinsuch metal surface portion means may absorb hydrogen to form at leastone metal hydride surface portion.

In accordance with another preferred embodiment hereof, this inventionprovides a hydrogen energy system comprising: hydrogen storer means,comprising at least one disk, for storing at least one substantialamount of hydrogen; wherein such hydrogen storer means comprises centralspin axis locator means for locating at least one central spin axis ofsuch at least one disk; wherein such at least one disk may rotate aboutsuch at least one central spin axis of such at least one hydride disk;wherein such hydrogen storer means comprises spinner motor gripper meansfor being by at least one motor driven spinner; wherein such spinnermotor gripper means is substantially concentric to such at least onecentral spin axis; wherein such spinner motor gripper means enables suchat least one disk to be spun about such at least one central spin axisof such at least one disk by such at least one motor driven spinner; andwherein during spinning, such at least one disk spins substantiallystably.

In accordance with another preferred embodiment hereof, this inventionprovides such a system wherein such at least one metal surface portioncomprises at least one pattern of cavities structured and arranged toprovide substantially uniform porosity. In accordance with anotherpreferred embodiment hereof, this invention provides such a systemwherein such at least one pattern of cavities comprises at least oneangle, with respect to such at least one metal surface portion, of about45°. In accordance with another preferred embodiment hereof, thisinvention provides such a system wherein each of such cavities comprisesa diameter of about 50 μm. In accordance with another preferredembodiment hereof, this invention provides a system wherein such atleast one metal surface portion comprises precipitated magnesium plateadapted to be cut into disks and contain such holes. In accordance withanother preferred embodiment hereof, this invention provides such asystem wherein such at least one metal surface portion comprisesmagnesium hydride. In accordance with another preferred embodimenthereof, this invention provides such a system wherein such at least onemetal surface portion comprises a plurality of non-porous strut portionsstructured and arranged to add stiffness. In accordance with anotherpreferred embodiment hereof, this invention provides such a systemwherein such at least one metal surface portion comprises at least onethin, stiff non-magnesium frame structured and arranged to addstiffness. In accordance with another preferred embodiment hereof, thisinvention provides such a system wherein such at least one metal surfaceportion comprises at least one thin surface-coating substantiallycomprising nickel and Mg₂Ni. And, it provides such a system wherein suchat least one photonic exciter comprises at least one array of lasers. Inaccordance with another preferred embodiment hereof, this inventionprovides such a system wherein such at least one catalyst comprisesnickel. In accordance with another preferred embodiment hereof, thisinvention provides such a system wherein such at least one catalystcomprises palladium.

In accordance with another preferred embodiment hereof, this inventionprovides a method, relating to manufacturing at least one hydrogenstorer, comprising the steps of: precipitating at least one hydrogenstorer material adapted to store hydrogen; cutting such at least onehydrogen storer material into at least one geometric shape; perforatingsuch at least one hydrogen storer material; etching at least one surfaceof such at least one hydrogen storer material with at least onechemical; washing such at least one surface to remove such at least onechemical; embedding, in such at least one surface, at least one catalyststructured and arranged to assist hydrogenation of such at least onesurface; coating such at least one surface with at least one surfacereaction preventer; whereby such method produces at least one hydrogenstorer. Further, it provides such a method wherein such at least onegeometric shape comprises at least one disk. Even further, it providessuch a method wherein the step of perforating comprises the step ofdrilling at least one hole. Even further, it provides such a methodwherein the step drilling comprises at least one laser. Even further, itprovides such a method wherein such at least one chemical comprises HCl.Even further, it provides such a method wherein such at least onesurface reaction preventer comprises nickel and Mg₂Ni. Even further, itprovides such a method wherein such at least one hydrogen storermaterial comprises magnesium. In accordance with preferred embodimentshereof, this invention provides for each and every novel feature,element, combination, step and/or method disclosed or suggested by thispatent application.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a partial side view of a preferred hydride disk,illustrating release of hydrogen gas, preferably by laser heating,according to a preferred embodiment of the present invention.

FIG. 2 shows a cutaway perspective view, illustrating a preferred diskplayer, according to the preferred embodiment of FIG. 1.

FIG. 3 shows a top view, illustrating a preferred disk, according to thepreferred embodiment of FIG. 1.

FIG. 4A shows a side view of a preferred disk, illustrating a preferredsurface preparation, according to the preferred embodiment of FIG. 1.

FIG. 4B shows a side view of the preferred disk, illustratingintroduction of preferred hydrogenation catalysts, according to thepreferred embodiment of FIG. 3.

FIG. 5 shows a diagrammatic view of a preferred stainless-steelhigh-temperature pressure reactor, illustrating hydrogenation of aplurality of the preferred disks on a preferred spindle, according tothe preferred embodiment of FIG. 4.

FIG. 6 shows a diagrammatic view, illustrating at least one preferredholding container for a plurality of the preferred hydride disks,according to the preferred embodiment of FIG. 1.

FIG. 7A shows a diagrammatic view of at least one preferred mineral oilremoval system, illustrating removal of the preferred optically clearmineral oil from the preferred hydride disk, according to the preferredembodiment of FIG. 6.

FIG. 7B shows a diagrammatic view of the mineral oil removal system,illustrating removal of residual mineral oil from the preferred hydridedisk, according to the preferred embodiment of FIG. 7A.

FIG. 8 shows a diagrammatic view, illustrating at least one preferredhydrogen supply system, according to the preferred embodiment of FIG. 1.

FIG. 9 shows a diagrammatic view of at least one preferred hydrogenrecharging system, illustrating preferred re-hydrogenation of a usedhydride disk, according to the preferred embodiment of FIG. 1.

FIG. 10 shows a diagram illustrating at least one preferred refuelingmethod according to the preferred embodiment of FIG. 1.

FIG. 11 shows a diagram illustrating at least one preferred diskexchange method according to the preferred embodiment of FIG. 1.

FIG. 12A shows a plan view illustrating at least one hydride diskaccording to a preferred embodiment of the present invention.

FIG. 12B shows a magnified view of such preferred hydride disk accordingto the preferred embodiment of FIG. 12A.

FIG. 13 shows an enlarged view of section 13-13 of FIG. 12B.

FIG. 14 shows a diagrammatic view, illustrating the atomic order of suchpreferred hydride disk, according to the preferred embodiment of FIG.13.

FIG. 15 shows a flow chart, illustrating at least one hydride diskmanufacturing process, according to the preferred embodiment of FIG. 14.

FIG. 16 shows a diagrammatic view, illustrating at least one sheetmanufacturing process, according to the preferred embodiment of FIG. 15.

FIG. 17 shows a diagrammatic view of at least one drilling chamber,illustrating at least one perforating process, according to thepreferred embodiment of FIG. 15.

FIG. 18 shows a diagrammatic flow chart, illustrating at least onehydrogenation process, according to the preferred embodiment of FIG. 15.

FIG. 19 shows a chart view illustrating temperature staging processes,during hydrogenation processes, according to the preferred embodiment ofFIG. 18.

FIG. 20 shows a perspective view, illustrating a preferred spacer,according to the preferred embodiment of FIG. 18

FIG. 21A shows a plan view illustrating at least one hydride diskaccording to an alternate preferred embodiment of the present invention.

FIG. 21B shows a magnified view of such preferred hydride disk accordingto the preferred embodiment of FIG. 21A.

FIG. 22 shows an enlarged view of section 22-22 of FIG. 21B.

FIG. 23 shows an enlarged view of section 22-22 of FIG. 21B according toan alternately preferred embodiment of the present invention.

FIG. 24 shows a diagrammatic view of at least one filtered cathodic arcdeposition apparatus according to an alternately preferred embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE BEST MODES AND PREFERRED EMBODIMENTS OF THEINVENTION

Hydrogen absorption within reversible metal hydrides (including metalalloys) may be used as hydrogen storage devices. Applicant has found, bytesting, that adsorbing hydrogen (as by destabilizing hydrogen bonds)from such metal hydrides at reasonable temperatures and with reasonableenergy expenditures may be best accomplished by very finely controlledheating. It has been found that this may provide an economical return ofgreater than about 5% (by weight) of hydrogen from a storage medium,with minimal energy consumption and system weight.

It is desirable to increase the absorbed hydrogen mass within the metalhydride while simultaneously reducing the energy required to release thehydrogen. Applicant has found that metallic alloys and metallic cappinglayers, along with metal-doped chemical and organic carriers, areexcellent storage media for hydrogen. However, one primary obstacle toreleasing hydrogen, from such storage media, is a need for heat, sincedecomposition temperatures are typically greater than 200° C.

Applicant has determined that laser heating of magnesium hydride is onepreferred method for extracting hydrogen, with available technology andminimal energy cost. Employment of at least one laser diode, usingpulsed-power, preferably provides ample heating of magnesium hydride torelease hydrogen, as shown in FIG. 1. Applicant has found, includingthrough experimentation, that less than about 80 continuous watts areneeded to heat enough magnesium hydride to release about 10 lbs (4.5 kg)of hydrogen at rates of up to about 2 lbs (0.9 kg) per hour. Such ratesof hydrogen may theoretically provide internal combustion, hybrid, andhydrogen-fuel-cell vehicles a range in excess of about 200 miles, whileadding less than about 330 lbs (150 kg) and about 6.3 cubic feet (0.18cubic meters) or about 47 gallons (178 liters). Conventional CD (compactdisk) motors, along with modified laser circuitry, may preferably exposeat least one magnesium hydride disk to at least one laser beam atrotations of up to about 24,000 rpm.

FIG. 1 shows a partial side view of at least one hydride disk 110,illustrating release of hydrogen gas 150 preferably by laser heating,according to a preferred embodiment of the present invention. Hydrogenenergy system 100 preferably comprises embodiment 101, as shown. Hydridedisk 110 preferably comprises at least one metal hydride, preferablysubstantially magnesium hydride. As discussed herein, concentration ofhydrogen, stored in hydride disk 110, preferably should be greater thanabout 5% by weight, for economical efficiency. Magnesium hydridetheoretically maximally stores about 7.6% hydrogen by weight. Uponreading this specification, those skilled in the art will now appreciatethat, under appropriate circumstances, considering such things as thenavailable forms of metal hydride, abilities to place such forms in arotatable “disk” shape structure for use with controlled laser heating,etc., other “disks” than unitary and/or complete “disks”, suchsegmented, liquid, or non-unitary “disks”, etc., may suffice.

Heating of hydride disk 110 preferably comprises localized heating byphotonic excitation using at least one coherent light source 160, asshown. Coherent light source 160 preferably comprises at least onesemiconductor laser diode 165, as shown. Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances, considering such things as then availablelight sources, cost, used hydrogen storage medium, etc., other lightsources, such as focused sunlight, phosphorescent light, biochemicallight, etc., may suffice. Semiconductor laser diode 165 preferablyproduces a beam of coherent light 170, as shown, preferably betweenabout 530 nm and about 1700 nm in wavelength, preferably about 784 nm inwavelength and with preferably between about 200 mW and about 2000 mW ofpower, preferably about 200 mW of power. Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances, considering such things as then availablelasers, cost, used hydrogen storage medium, etc., other wavelengths ofcoherent light, such as other infrared wavelengths, visible spectrum,ultraviolet, etc., may suffice. To assist keeping semiconductor laserdiode 165 from overheating, power is preferably pulsed instead ofcontinuous.

Preferably, as coherent light 170 adsorbs hydrogen gas 150, size ofhydride disk 110 will preferably initially increase due to thermalexpansion and then preferably reduce to pre-hydrogenated volumes. Somesmall amount of hydrogen movement from higher concentration to lowerconcentration theoretically can be expected in hydride disk 110 afteradsorption of a particular track; but applicant has found such movementto be inconsequential in most circumstances.

Preferably, coherent light source 160 further comprises at least onedefocusing lens 162, as shown. Defocusing lens 162 preferably altersfocus of coherent light 170 to form at least one defocused laser beam168, as shown. Defocused laser beam 168 preferably comprises at leastone beam radius 136 at surface 140, as shown. Beam radius 136 preferablyranges between about 10 nm and about 2 mm, preferably about 15 nm, asshown. Clearance 174 between defocusing lens 162 and surface 140preferably is about two millimeters, as shown, assisting protectingdefocusing lens 162 from impacting surface 140 due to slightdeformations that may occur in surface 140.

Applicant has determined, including by testing, that decomposition ofmagnesium hydride using at least one surface temperature of about 390°C., in a vacuum at about −5 bar, is reached within about 10 ns withenough conductivity to release 100% of stored hydrogen (up to about 7.6wt %) within beam radius 136, to a depth of about 20 micrometers. At atleast one maximum effective decomposition distance 145 comprising about½ mm, the temperature decreases to about 280° C., dropping release ofstored hydrogen to about 39.5% of maximum (up to about 3 wt %). Sincemagnesium typically melts at about 650° C., applicant has found that asurface temperature of about 390° C. (60% of melting temperature)roughly minimizes adiabatic evaporation of magnesium.

Coherent light source 160 preferably rides on at least one rail 175,preferably moving radially, near at least one surface 140 of hydridedisk 110, as shown. Hydride disk 110 preferably spins about a centralaxis 215 (see FIG. 2), preferably positioning surface 140 for defocusedlaser beam 168 to induce heating, as shown.

Absorptivity to infrared radiation is inversely proportional to thermalconductivity. Applicant has determined that, unlike for magnesium,thermal conductivity of magnesium hydride increases with risingtemperature, attributable to radiation and “the Smoluchowski effect”(described in Marian Smoluchowski's paper ‘Zur kinetischen Theorie derBrownshen molekular Bewegung and der Suspensionen’ in Annalen derPhysik, 21, 1906, 756-780). Heat capacity is also greater in magnesiumhydride as compared to magnesium. Magnesium has a specific heat capacityof about 1050 J/(kg·K) (at 298 K) and the specific heat capacity ofmagnesium hydride is about 1440 J/(kg·K) (at 298 K). Further,magnesium's thermal conductivity is about 156 W/(m·k), while magnesiumhydride's thermal conductivity is about 6 W/(m·k).

One formula, as determined by applicant, for thermal diffusivity (a) (afactor in the depth of thermal penetration), using thermal conductivity(λ), density (p), and specific heat (c) is:a=λ/ρc

Calculating thermal diffusivity for magnesium hydride gives:a=(6 W/(m·K)/(0.001450 kg/m³×1440 J/(kg·K))=2.87×10⁶ J/(m³K)

Using this calculation of thermal diffusivity for magnesium hydride,applicant estimates thermal penetration (Z), based on a pulse time of115 ns at 4× rotational speeds and 19 ns at 48× rotational speeds, as:Z=√(4·a·t)=36334 nm at 4×(0.036 mm)Z=√(4·a·t)=14769 nm at 48×(0.015 mm)

Estimated thermal penetration is inadequate for release of all storedhydrogen in hydride disk 110 by a factor of about 30, for a 1 mmthickness. Applicant has determined, however, that since magnesiumhydride has a refractive index of about 1.96, which provides about 80%transparency, that optical penetration may aid in increasing release ofstored hydrogen. Applicant has found that, through modification of powerdensity to find at least one optimal power setting and beam radius 136,maximum effective decomposition distance 145, comprising about ½ mm, maybe reached, as shown. In order to instigate hydrogen adsorptionsubstantially through thickness 144 of hydride disk 110, preferably,defocused laser beam 168 may also be incident upon opposing surface 142.

Power density, mathematically defined as:E=q/π·r ²

where q is beam power and r is beam radius, determines peak temperature,near surface 140, and thermal interaction at interface 172 of hydridedisk 110 and defocused laser beam 168. Applicant has found that a powerdensity capable of adsorbing hydrogen from magnesium hydride need onlybe concerned with the melting point of magnesium.

For magnesium hydride, coherent light source 160 preferably produces atleast one temperature profile 130 in hydride disk 110, due to thermalinteraction at interface 172, as shown. Temperature profile 130preferably ranges from about 390° C., near surface 140, to about 280° C.at maximum effective decomposition distance 145, as shown.

Applicant has found by testing that, after the course of repeatedhydrogen absorption and desorption cycles, the fabricated disks appearlose the ability to absorb hydrogen to the full extent (0.345 wt %)initially noted when the disks were new. Analysis of the disks indicatedthat contaminants had blocked interstitial spaces and eventually coatedareas along the surface of the disks. These contaminants might beconsidered (theoretically) to be related to the lack of 100% purity andmay be to be an inevitable consequence of the hydrogen source.

In testing and analysis of the previously mentioned lower-capacitydisks, there was evidence of deuterium in the form of observed Time ofFlight (“ToF”) hydrogen deuterium (“HD”) signals which were not evidentin new disks. Time of Flight does not provide quantitative analysis, andtesting did identify the isotopes of hydrogen. A Secondary Ion MassSpectrometry (SIMS) study may be necessary to determine evidence ofincreased concentration with each absorption and desorption cycle.

The evidence of detectable amounts of deuterium in desorbed disks maytheoretically be explained by the stable, but larger structure of the HDmolecule, along with its permanent dipole moment. These characteristicsmay explain limited desorption of deuterium from the medium. Reducingthe laser pulse length into the tens of femtoseconds would increasephoton absorption by this molecule and potentially increase desorption.However, this approach may not reduce the general rise in contaminationby other elements.

An explanation of the contamination by deuterium is inconclusive. Thepredominant theory is that the molecules of HD and D₂ and even MgD₂ aremore stable, individually and within the metal lattice, to theparticular wavelengths and energy densities selected for desorption ofH₂ from Mg₂NiH₄+MgH₂. Over multiple cycles (using this theory), theconcentration of deuterium rises in the material and reduces therecharging capability.

According to a less predominant theory, it may be suspected that atransmutation may occur due to: (1) the high degree of ionizationafforded within the beam channels and (2) the fact that the molecularions entering into the beam channels are subjected to intense vibrationand oscillation in the presence of a nano-scale level electrostatic iontrap with increasing potentials. Support for this less predominanttheory may be found in: (1) occasions of thermal run-away in whichunexplained increases in temperature are clearly detected and (2) thefailure of the material to return to ambient temperature within thetimeframe expected for the power density and EM pulse directed at thematerial.

FIG. 2 shows a cutaway perspective view, illustrating at least onepreferred disk player 210, according to the preferred embodiment ofFIG. 1. As shown, disk player 210 preferably comprises at least onespinning motor 230, coherent light source 160 and disk changingmechanics. Such disk changing mechanics preferably accept at least onehydride disk 110, preferably move such at least one hydride disk 110 tospinning motor, and preferably remove such at least one hydride disk110, once expended, from disk player 210. Spinning motor 230 preferablyspins hydride disk 110 to achieve at least one linear motion of up toabout 63 meters per second, preferably while coherent light source 160liberates hydrogen gas 150 from hydride disk 110, as shown. Disk player210 preferably operates under vacuum between about −1 torr to about −5torr. Such vacuum preferably serves to evacuate liberated hydrogen gas150, as shown in FIG. 1, and preferably maintains a neutral atmospherearound hydride disk 110.

At least one control circuit 220, as shown, preferably adjusts speed ofspinning motor 230, preferably moves coherent light source 160 on rail175, and preferably adjusts power output of coherent light source 160(at least embodying herein at least one photonic exciter structured andarranged to photonically excite such at least one hydrogen storer toassist release of the stored hydrogen from such at least one hydrogenstorer) to preferably optimize release of hydrogen gas 150. Output ofhydrogen gas 150 is preferably optimized to demand for hydrogen gas 150from at least one hydrogen-driven device 830 (see discussion relating toFIG. 8).

Applicant has determined that disk player 210 may preferably bereconfigured from existing compact disc writer (CD-R) technology.Applicant adapted at least one CD writer drive (“Iomega model 52x” CDRWdrive) to adsorb stored hydrogen from hydride disk 110. In order toadapt such at least one CD writer to use hydride disk 110, at least onecontrol circuit 220, as shown, preferably bypasses internal feedbackcontrols of such at least one CD writer drive. Rather than relying onfeedback information, control circuit 220 preferably uses directmanipulation of controlled components of disk player 210, preferablyallowing precise control. Further, internal laser of CD writerpreferably may be used provided such laser fulfills requirements givenfor semiconductor laser diode 165.

Manufacturing Magnesium Hydride Disks

FIG. 3 shows a top view, illustrating at least one disk 315 according toembodiment 101 of FIG. 1. Such at least one disk 315 is preferablyformed by cutting from at least one sheet preferably comprising at leastone material capable of absorbing hydrogen, preferably metal, preferablymade substantially of magnesium, preferably AZ31B (availablecommercially). Upon reading this specification, those skilled in the artwill appreciate that, under appropriate circumstances, considering suchthings as available materials, economics, stored hydrogen density, etc.other materials capable of absorbing hydrogen, such as other metals,plastics, glass, etc., may suffice. Upon reading this specification,those skilled in the art will appreciate that, under appropriatecircumstances, considering such things as safety, economics, materialsused, etc. other disk formation methods, such as using injection molds,machining, laser cutting, etc., may suffice.

Disk 315 is preferably cut using at least one water cutter, alternatelypreferably using at least one stamp cutter. Disk 315 preferably is aboutone millimeter thick. Diameter 370 of disk 315 is cut preferably tobetween about 50 mm and about 150 mm, preferably about 120 mm. A centerhole 360 is preferably cut in disk 315, preferably between about fivemillimeters and about 15 millimeters in diameter, preferably about 15millimeters. Preferably, center hole 360 allows disk 315 to be centeredfor stable spinning. Disk 315 preferably comprises at least one ring 365concentric to center hole 360 (at least embodying herein wherein such atleast one hydrogen storer comprises at least one central spin axislocator structured and arranged to locate at least one central spin axisof such at least one disk) preferably providing at least one frictiongrippable surface preferably to allow application of rotational torqueto spin disk 315, as shown (this arrangement at least embodying hereinwherein such at least one disk comprises at least one spinner motorgripper capable of being gripped by at least one motor driven spinner).

FIG. 4A shows a side view of preferred disk 315, illustrating surfacepreparation, according to embodiment 101 of FIG. 1. Preferably, afterfabrication, oxidization layers, vapor deposits and other physicalobstructions to hydrogenation must be removed from disk 315. Surfaces346 of disk 315 preferably may be smoothed to a mirror-like finish withirregularities of preferably less than two micrometers whileincorporating small amounts of hydrogenation catalysts. Additionally,disk 315 preferably is structurally balanced so, when spun, surfaces 346have minimal wobbling. Irregularities of surfaces 346 may be distorted,by the addition of hydrogen gas 150, up to approximately 2½ micrometersas disk 315 expands.

Disk 315 preferably is lightly sanded with titanium oxide to removesurface oxidation. Disk 315 preferably is then washed with 2% HF toremove bulk oxides and then preferably with dilute pepsin/HCL cleaningsolution to remove residual sub-oxides. A plurality of such disks 315are preferably stacked on at least one spindle 345 with at least onestainless steel washer 520, as shown in FIG. 5, between each disk 315.Dimensions of stainless steel washer 520 preferably comprise about 15.3mm in inner diameter, about 18 mm in outer diameter, and about fourmillimeters in thickness. Spindle 345 preferably comprises steel,preferably stainless steel. Spindle 345 preferably comprises a diameterof about 14.9 mm. Spindle 345 preferably is positioned in vacuum chamber310, as shown. At least one vacuum chamber 310 is preferably purged withnitrogen. Vacuum chamber 310 is brought to preferably about 0.7 torr(0.014 psi) (0.001 bar) for preferably about one hour. After about 1hour, the plurality of such disks 315, on spindle 345, preferably isrotated at about 18,000 rpm. At least one spray nozzle 330, preferablydesigned for blasting at least one powder 340, preferably is at a fixeddistance from disk 315, as shown. Powder 340 preferably comprises nickelpowder, comprising a particle-size range of preferably about 2.6micrometers to about 3.3 micrometers, preferably nickel powdercommercially available as “Inco Type 287”. Powder 340 is preferablyblasted onto disk 315, as shown, at about 50 psi preferably using argongas. Disk 315 preferably is subsequently sandblasted with progressivelysmaller 99.9+% nickel particles, preferably from about −325 mesh toabout −500 mesh (American Elements CAS no. 7440-02-0) at preferablyabout 40 psi using preferably nitrogen gas.

FIG. 4B shows a side view of disk 315, illustrating introduction ofpreferred hydrogenation catalysts 440, according to embodiment 101 ofFIG. 1. Inside vacuum chamber 310, disk 315 is preferably furthertreated with hydrogenation catalysts 440, as shown. Hydrogenationcatalysts 440 preferably comprise at least one submicron powder 445, asshown. Hydrogenation catalysts 440 preferably are each applied forbetween about 10 minutes and about 15 minutes at preferably about 35psi. Each of preferably three submicron powders 445 preferably comprisesa purity of greater than about 99.999%. One Submicron powder 445preferably comprises 99.999+% nickel. Another submicron powder 445alternately preferably comprises 99.999+% palladium. Yet anothersubmicron powder 445 alternately preferably comprises 99.999+% titanium.Upon reading this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchthings as then available materials, other catalyst technologies, cost,hydride material used, etc. other catalysts, such as other metals,plastics, resins, slurries, etc., may suffice.

Hydrogenation catalysts 440, preferably as described, preferably areserially applied such that application of all hydrogenation catalysts440 comprises between about 30 minutes and about 45 minutes. The amountof hydrogenation catalysts 440 used is insufficient for capping, andinstead preferably serves as a “door man” to preferably keep hydrogenmoving past outer layer of surfaces 346 where magnesium hydrideformation and buildup could prevent further absorption of hydrogen.Surface preparation and treatments with hydrogenation catalysts 440preferably provides necessary surface smoothness and preferablyimpregnates, through adhesion, a preferred amount of hydrogenationcatalysts 440 without significant ablation of surfaces 346.

Vacuum chamber 310 preferably is then returned to atmospheric pressure,preferably with nitrogen, and disk 315 preferably is removed to at leastone stainless-steel high-temperature pressure reactor 510, as shown inFIG. 5. Stainless-steel high-temperature pressure reactor 510 preferablyis nitrogen-purged with 0.1 torr on the evacuation cycle, preferablythrough at least two purging cycles to prepare for hydrogenation. Disk315 preferably is then ready for hydrogenation.

FIG. 5 shows a diagrammatic view of stainless-steel high-temperaturepressure reactor 510, illustrating preferred hydrogenation of disk 315on spindle 345, according to embodiment 101 of FIG. 1. At least oneheating element 560 preferably heats stainless-steel high-temperaturepressure reactor 510, as shown, from preferably about 20° C. topreferably about 350° C. The coefficient of thermal expansion (a) ofmagnesium is about 27·10⁻⁶/° C., which provides that disk 315 willexpand from a diameter of about 120 mm to about 121 mm when raised fromabout 20° C. to about 350° C. Because being raised from about 20° C. toabout 350° C. effects closing of diameter of central hole by as much asabout ½ mm, prevention of size reduction of central hole by thermalexpansion or hydrogenation is necessary. The plurality of disks 315 arepreferably placed on spindle 345, as shown, in order to prevent centralhole closing. The coefficient of thermal expansion of stainless steel isabout 17×10⁻⁶/° C. Spindle 345 expands from about 14.9 mm, at about 20°C., to about 15 mm in diameter, at about 350° C. Since magnesium is lessdense than stainless steel, spindle 345 preferably constrains disk 315to expand vertically and radially outward as disk 315 is heated andhydrogenated.

Thermal and internal strain from forced expansion away from spindle 345theoretically reduces absorption of hydrogen near center hole 360 ofdisk 315, approximately within ring 365. Such reduction in absorption isinconsequential since central area of hydride disk 110, including ring365, is preferably not lased. Furthermore, heating is preferablyincremented slowly to allow enough time for thermal equilibrium andexpansion without undue stress. Such slow heating is preferablyaccompanied by slow increases in pressure. Hydrogenating slowlypreferably allows greater absorption of hydrogen gas 150 because buildup of magnesium hydride does not occur near surfaces 346 impedingcomplete hydrogenation.

Pressure is preferably raised to atmospheric pressure with hydrogen gas150 and at least one thermocouple 550, as shown, is preferably set toabout 21.1° C. to establish initial temperature. Small increments oftemperature and pressure preferably are applied preferably over about 6hours to preferably raise pressure to about 35 bar (500 psi) andtemperature to preferably about 350° C. Final temperature and pressureare preferably maintained for about an additional 2 hours.

At least one step motor 554, which preferably can rotate disk 315 atabout 18,000 rpm, preferably comprises at least one axle 552, as shown.Axle 552 is preferably passed into stainless-steel high-temperaturepressure reactor 510, as shown. Spindle 345 is preferably attached toaxle 552, as shown, allowing step motor 554 to spin spindle 345 insidestainless-steel high-temperature pressure reactor 510. Rotation at about18,000 rpm preferably allows additionally between about 700 psi andabout 3000 psi to be exerted radially on disk 315, once initialhydrogenation is complete, and preferably allows a small amount ofhydrogen “over loading”. Step motor 554 is preferably activated to spinspindle 345 and disk 315 at preferably about 18,000 rpm for about 1hour. Afterwards, disk 315 preferably is slowed to a stop and preferablyallowed to remain at full pressure and temperature for about 1 hourmore.

Hydride disk 110 preferably is formed as Disk 315 preferably becomesfully hydrogenated to nearly 100% magnesium hydride preferably with ahydrogen content of about 7.6%. Disk 315 theoretically growsdimensionally during hydrogenation by as much as about 17%, but thesurface area of hydride disk 110 to be lased preferably remains thesame. Hydride disk 110 is highly reactive in air, and great cautionshould be taken in handling and storage.

Magnesium hydride ignites spontaneously in air to form magnesium oxideand water. Such ignition is a violent reaction, which cannot be stoppedby addition of water or carbon dioxide. Therefore, consideration of thepracticality of creating, storing, and transporting hydride disks 110,comprising magnesium hydride, is important. Hydride disk 110 preferablyis stored in at least one inert environment.

Before removing hydride disk 110 from stainless-steel high-temperaturepressure reactor 510, pressure should preferably be allowed to return toatmospheric pressure through release of hydrogen gas 150. Then,optically clear mineral oil 610 (preferably “Sontex LT-100”) ispreferably pumped into stainless-steel high-temperature pressure reactor510, preferably to displace any remaining hydrogen gas 150.Stainless-steel high-temperature pressure reactor 510 may be openedpreferably only after a volume of optically clear mineral oil 610, equalto the interior volume of stainless-steel high-temperature pressurereactor 510 less the volume of hydride disk 110 and spindle 345, hasbeen pumped.

Alternately, hydride disks 110 are preferably stored in a light (−1 to−2 bar) vacuum. When storing in such light vacuum, optically clearmineral oil 610 need not be applied to hydride disks 110. By notapplying optically clear mineral oil 610, other special handling toaccount for optically clear mineral oil 610 may be preferably bypassed.Upon reading this specification, those skilled in the art will nowappreciate that, considering such issues as cost, future technologies,etc., other inert environments, such as, for example, inert gasses,other inert fluids, coatings, etc., may suffice.

Optically clear mineral oil 610, as shown, (preferably C_(n)H2_(n+2))preferably comprises a highly purified organic aliphatic hydrocarbon,preferably comprising an index of refraction of about 1.47 and a lighttransmittance of about 0.99972. Optically clear mineral oil 610preferably does not interact with hydride disk 110. Optically clearmineral oil 610 preferably acts as an atmospheric insulator to preventoxidation and static discharge. Upon reading this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances, considering such things as wavelength of light source,cost, available materials, etc., other atmospheric insulators, such asresins, other oils, solutions, etc., may suffice.

In addition, flow of hydrogen, due to concentration differences, isminimal due to inherently high hydrogen content of optically clearmineral oil 610. Preferably, care should be taken to avoid any moisturecontent in optically clear mineral oil 610, as well as in manufacturingenvironment, when stainless-steel high-temperature pressure reactor 510is opened. Such moisture may cause formation of hydrogen peroxide (H₂O₂)in optically clear mineral oil 610. In addition, ambient air preferablyshould be as dry as possible, also to preferably prevent hydrogenperoxide development in optically clear mineral oil 610. Optically clearmineral oil 610 preferably has a loss of only about 0.028% of lightpassing through. Preferably, optically clear mineral oil 610 has amolecular weight of about 40.106, a flash point of about 135° C., aspecific gravity greater then 0.8, and a boiling point approximately300° C. Hydride disk 110 preferably may now be removed fromstainless-steel high-temperature pressure reactor 510 and preferablyimmediately placed in at least one holding container 600 of opticallyclear mineral oil 610, as shown. Preferably, optically clear mineral oil610 remains around hydride disks 110 to prevent contact with air. Asmentioned, such contact may result in a violent reaction creating amagnesium fire.

FIG. 6 shows a diagrammatic view, illustrating at least one holdingcontainer 600 for a plurality of hydride disks 110, according toembodiment 101 of FIG. 1. Transfer of hydride disk 110 fromstainless-steel high-temperature pressure reactor 510 to optically clearmineral oil 610 in holding container 600 preferably should only beperformed with proper safety apparel and adequate fire suppressionavailable. An understanding of proper handling and methods of fireextinguishing of magnesium hydride is paramount. The informationprovided in this application is not an adequate substitute for propertraining. Eye protection should be worn (preferably a welder's mask)because of the brilliance of a magnesium fire. Also, heat and fireresistant clothing should be worn due to the intensity of a magnesiumhydride fire. Sand, in plastic bags, should preferably be available toplace on a fire should one erupt. Tabletops and flooring shouldpreferably be of soap stone or other inert material, not metal or wood.Carbon dioxide (CO₂) extinguishers or water should never be used on amagnesium fire, since such extinguishers promote the reaction.Alternately, holding container 600 preferably maintains a light vacuumfor storage of hydride disk 110, negating need for optically clearmineral oil 610.

FIG. 7A shows a diagrammatic view of at least one mineral-oil removalsystem 700, illustrating removal of optically clear mineral oil 610 fromhydride disk 110, according to embodiment 101 of FIG. 1. When usingoptically clear mineral oil 610, optically clear mineral oil 610preferably is removed from hydride disk 110, using mineral-oil removalsystem 700. The heat of vaporization of optically clear mineral oil 610,comprising about 214 kJ/kg, is particularly important. The moreoptically clear mineral oil 610 left on hydride disk 110, the more powerneeded to efficiently adsorb the stored hydrogen, since optically clearmineral oil 610 left on hydride disk 110 will absorb a portion of theheat generated by coherent light 170.

Mineral-oil removal system 700 preferably comprises at least one diskspinner 710, as shown. Disk spinner 710 preferably comprises at leastone spinner motor 715, as shown. Disk spinner 710 preferably operates inan area of negative pressure. Disk spinner 710 preferably may be adaptedfrom at least one CD drive. To adapt such at least one CD drive, allelectronic components preferably must be shielded from exposure tooptically clear mineral oil 610, preferably by at least one polymer,preferably polyvinyl. Prior to use, hydride disk 110 is preferably movedinto disk spinner 710, as shown, and preferably spun by spinner motor715 to about 24,000 rpm to recover most of optically clear mineral oil610, preferably for reuse.

FIG. 7B shows a diagrammatic view of mineral oil removal system 700,illustrating removal of residual mineral oil 712 from hydride disk 110,according to embodiment 101 of FIG. 7A. Mineral oil removal system 700preferably further comprises at least one residual mineral oil remover717, as shown. Residual mineral oil remover 717 preferably comprises atleast two opposing suction vacuums 720, as shown. After spinning,opposing suction vacuums 720 preferably pump off any residual mineraloil 712, comprising optically clear mineral oil 610, for reuse, asshown. Opposing suction vacuums 720 preferably substantially coverdiameter of hydride disk 110, as shown. 100% recovery, of opticallyclear mineral oil 610, may not be possible without vaporization duringlasing of hydride disk 110. Minimization of vaporization preferablyminimizes energy consumption of the lasing process. Vaporized mineraloil preferably should be collected for ecological and safety reasons.After removing optically clear mineral oil 610, hydride disk 110preferably is passed to disk player 210, as discussed in FIG. 8, forhydrogen adsorption, as discussed herein (See FIGS. 1 & 2).

FIG. 8 shows a diagrammatic view, illustrating at least one hydrogensupply system 800, according to the preferred embodiment of FIG. 1.Hydrogen supply system 800 preferably comprises holding container 600,mineral oil removal system 700 and disk player 210, as shown. Hydridedisk 110 is preferably moved from holding container 600 to mineral oilremoval system 700, preferably for optically clear mineral oil 610removal, as shown. After optically clear mineral oil 610 issubstantially removed, hydride disk 110 preferably transfers to diskplayer 210 for hydrogen adsorption, as shown. After completing at leastone adsorption process, used hydride disk 910 preferably is returned toholding container 600, as shown, for safe storage. Processing of hydridedisk 110 is preferably conducted under negative pressure (about −1 torr)preferably to allow for hydrogen collection and preferably preventingexposure of hydride disk 110 to air.

Unlike magnesium hydride, exhibiting 80% transparency, magnesiumexhibits mirror like opacity, when manufactured as discussed herein.Transparency variation of hydride disk 110 from used hydride disk 910therefore preferably indicates hydrogen content. Such transparencyvariation may preferably be used to distinguish at least one usedhydride disk 910 from such at least one hydride disk 110, and may alsopreferably be used as at least one “gas” gauge 880. At least onetransparency probe 850 preferably polls stored disks 860. Transparencyinformation passes to at least one processor 870 where quantities ofsuch at least one hydride disk 110 and such at least one used hydridedisk 910 are determined. At least one value is then calculated foravailable hydrogen stores and may be displayed as such at least one“gas” gauge 880.

Hydrogen supply system 800 preferably further comprises at least onecondensing tank 810, as shown. Gases released from processing maycontain vaporized mineral oil (when using optically clear mineral oil610), in addition to hydrogen gas 150. Such gases are preferablycollected and preferably pass into condensing tank 810. Condensing tank810 preferably comprises at least one cooling environment at atmosphericpressure. Optically clear mineral oil 610 is not dissociated into itsconstituent elements by vaporization in an anaerobic atmosphere.Optically clear mineral oil 610 is preferably recaptured withincondensing tank 810, as shown.

After condensation of optically clear mineral oil 610 in condensing tank810, hydrogen gas 150 is preferably supplied to hydrogen-driven device830. Alternately preferably, hydrogen gas 150 is pressurized in at leastone pressure tank 820 to at least one atmosphere of pressure, beforebeing supplied to hydrogen-driven device 830, as shown. Hydrogen gas 150supplied by hydrogen supply system 800 preferably maintains supply ofhydrogen gas required by hydrogen-driven device 830 to operate steadily.Pressure tank 820 preferably acts as a hydrogen gas reserve, allowingaccelerated use of hydrogen gas 150, for a limited time, beyond thehydrogen adsorption rate of hydrogen supply system 800. Pressure tank820 may preferably be sized to provide sufficient quantity according toat least one brief increased supply need of hydrogen-driven device 830.

Hydrogen-driven device 830 preferably comprises at least one vehicleengine adapted for using hydrogen gas 150. Such at least one vehicleengine preferably comprises at least one combustion engine, alternatelypreferably at least one hybrid engine, alternately preferably at leastone hydrogen power cell driven engine. Upon reading this specification,those skilled in the art will now appreciate that, under appropriatecircumstances, considering such things as then availability, cost,purpose, etc., other hydrogen-driven devices, such as cooking devices,generators, heaters, etc., may suffice. For application to such at leastone vehicle engine, pressure tank 820 preferably comprises a size ofabout two liters which may hold up to about ½ kg of hydrogen gas 150.Applicant has determined that, under relevant circumstances, anabout-two-liter size of pressure tank 820 allows for about a 30-secondburst of increased consumption for acceleration. After such 30-secondburst, pressure tank 820 may preferably recharge giving, as similarlydetermined by applicant, about a 50-second recovery time.

For hydrogen-driven device 830 comprising at least one typical vehicle,hydrogen supply system 800 should deliver a supply rate of about 1.3kg/hour of hydrogen to maintain better than 50 miles per hour. Thickness144, rotation speed of hydride disks 110, power of semiconductor laserdiode 165, and the number of semiconductor laser diodes 165 should beoptimized to reach such at least one supply rate. If semiconductor laserdiode 165 is too weak, then rotation speed of hydride disks 110 has tobe slowed in order to liberate enough hydrogen. The slowed rotationspeed of hydride disks 110 will then require a plurality ofsemiconductor laser diodes 165 and a plurality of disk players 210 tomaintain an adequate supply of fuel.

Applicant has determined, including by experimentation, that using onesemiconductor laser diode 165 (at about 760 nm) at an operating speed ofabout 2× (about 2.6 m/s) requires about 33 minutes to release about 1.2grams of hydrogen. Using this operating speed requires about 148 diskplayers 210 with about 8 semiconductor laser diodes 165 each to deliversuch at least one supply rate of about 1.3 kg per hour. This wouldrequire an additional 10 kg and 2 cubic feet to accommodate. The totallaser power comprises about 236 watts (0.32 horsepower) and such about148 disk players with disk changing mechanisms would require about 300watts (0.4 horsepower). Preferably, when using a plurality ofsemiconductor laser diodes 165, each semiconductor laser diode 165differs in power proportional to the distance from the center of hydridedisk 110, since actual linear speed is a function of the radius.Multiple semiconductor laser diodes 165 preferably may be replaced withat least one diode laser array, preferably at least one bar laser (thisarrangement at least herein embodying wherein such at least one photonicexciter comprises at least one array of lasers).

By comparison, applicant has determined, including by experimentation,that using another semiconductor laser diode 165 (at about 780 nm) at anoperating speed of about 48× requires only 3 minutes. At about 48×,about 14 disk players 210 with about 8 semiconductor laser diodes 165each delivers such at least one supply rate. Under these conditions,operating hydrogen supply system 800 requires about 0.25 horsepower.

Applicant has determined that the percentage of the power producedneeded to run hydrogen supply system 800, based on experimental findingsand a fuel cell efficiency of about 50%, comprises about one percent.

FIG. 9 shows a diagrammatic view of at least one hydrogen rechargingsystem 900, illustrating re-hydrogenation of used hydride disks 910,according to embodiment 101 of FIG. 1. At least one used hydride disk910 preferably recharges by passing into at least one hydrogen plasmastream 930, as shown. Hydrogen plasma stream 930 preferably compriseshighly charged hydrogen ions, as shown. Hydrogen plasma stream 930 ispreferably created from hydrogen gas injected preferably with at leastone microwave 920 and at least one radio wave 925, preferably at leasttwo microwaves 920 and such at least one radio wave 925, as shown.Microwave 920 is preferably generated from at least one microwavegenerator 922, as shown. Radio wave 925 is preferably generated from atleast one radio-wave generator 927, as shown (these generators at leastembodying herein at least one electromagnetic field generator structuredand arranged to generate at least one electromagnetic field sufficientto form at least one supply of hydrogen plasma). Hydrogen plasma stream930 preferably comprises a temperature of about 2000° C. Hydrogen plasmastream 930, being highly charged, preferably envelops used hydride disk910, as shown. As hydrogen plasma stream 930 envelops used hydride disk910, hydrogen plasma stream 930 will cool and is preferably absorbedinto used hydride disk 910, as shown. Hydrogen recharging system 900preferably exposes used hydride disk 910 to hydrogen plasma stream 930for about 0.15 seconds, preferably resulting in a recharged hydride disk915, as shown, preferably substantially similar to and about as useableas hydride disk 110. Preferably, hydrogen recharging system 900 mayproceed while used hydride disk 910 is within holding container 600,preferably reducing risk of combustion of recharged hydride disk 915.

FIG. 10 shows a diagram illustrating at least one refueling method 730according to embodiment 101 of FIG. 1. Hydrogen gas 150 preferably isstored at and manufactured in at least one factory 732, as shown, instep Manufacture and Store Hydrogen 735. Hydrogen gas 150 preferably istransported, in at least one hydrogen transportation vehicle 742, to atleast one refueling center 747, as shown, in step Transport Hydrogen toRefueling Center 740. At least one hydrogen-powered vehicle 750preferably refuels, preferably using hydrogen recharging system 900, asdescribed in FIG. 9, in step Recharge Magnesium Hydride Disks 745, asshown. Refueling method 730 preferably allows multiple cycles ofrefueling and use without replacing hydride disk 110.

FIG. 11 shows a diagram illustrating at least one disk exchange method760 according to embodiment 101 of FIG. 1. When such at least one usedhydride disks 910 are insufficiently rechargeable, used hydride disks910 may preferably be swapped out for hydride disks 110, as shown. Aplurality of such at least one hydride disks 110 are preferablymanufactured, as described in FIG. 3-6, in at least one factory 767 instep Manufacture Disks 765, as shown. Additionally, in step ManufactureDisks 765, materials required to manufacture hydride disks 110preferably may be recycled from used hydride disks 910, as shown. Aplurality of such at least one hydride disks 110 are preferablytransported, in at least one disk transportation vehicle 772, to atleast one service station 777, as shown, in step Transport Disks toService Station 770. Such transported plurality of such at least onehydride disk 110 (at least embodying herein at least one hydrogen storerstructured and arranged to store at least one substantial amount ofhydrogen) preferably are immersed in optically clear mineral oil 610during transport, as during storage in holding container 600 (see FIG.6). At service station 777, each used hydride disk 910 inhydrogen-powered vehicle 750 is preferably replaced with new hydridedisk 110 in step Exchange Disks 775, as shown. A plurality of usedhydride disks 910 are preferably transported back, in disktransportation vehicle 772, to factory 767 for recycling, as shown, instep Return Disks for Recycling 785.

FIG. 12A shows a plan view illustrating at least one hydride disk 1210according to a preferred embodiment of the present invention.

FIG. 12B shows a magnified view of hydride disk 1210 according to thepreferred embodiment of FIG. 12A.

Referring to FIGS. 12A and 12B, although most features of embodiment1200 are repeated from preferred embodiment 101, in embodiment 1200, asshown, embodiment 1200 preferably comprises hydride disk 1210, as shown.Hydride disk 1210 preferably comprises primarily magnesium hydride (atleast herein embodying wherein such at least one metal surface portioncomprises magnesium hydride). Upon reading this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances considering such issues as future materials, economics,stored hydrogen density, etc. other materials capable of absorbinghydrogen, such as other metals, plastics, glass, etc., may suffice.

Hydride disk 1210 preferably comprises a thickness 1212 of about ½ mm.Hydride disk 1210 preferably comprises an outer diameter 1214 of betweenabout 50 mm and about 150 mm, preferably about 120 mm. Hydride disk 1210preferably comprises an inner diameter of preferably between about 5 mmand about 15 mm, preferably about 15 mm. Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances considering such issues as future technology,cost, future applications, etc. other dimensions may suffice.

Hydride disk 1210 preferably further comprises at least one surface areaextender 1220, preferably perforations 1225 (see FIG. 13). Surface areaextender 1220 preferably increases the amount of surface area of hydridedisk 1210, which preferably reduces hydrogenation time and hydrogenationpressures. Each perforation 1225 preferably comprises a diameter ofpreferably between about 100 nm and about 50 μm, preferably about 50 μm(at least herein embodying wherein each of such cavities comprises adiameter of about 50 μm). Upon reading this specification, those skilledin the art will now appreciate that, under appropriate circumstancesconsidering such issues as material expansion, cost, future perforationmethods, etc. other dimensions may suffice.

Multiple perforations 1225 preferably are spaced about 150 μm apart(measured center-to-center). Perforations 1225 preferably comprise apolar array in arrangement, as shown. Upon reading this specification,those skilled in the art will now appreciate that, under appropriatecircumstances considering such issues as future technology, cost,materials, etc. other arrangements, such as, for example, linear arrays,hexagonal arrays, etc., may suffice.

Hydride disk 1210 preferably additionally comprises at least onestructural integrity maintainer 1230, as shown. Structural integritymaintainer 1230 preferably comprises at least one non-perforated “strut”or band 1235 (at least herein embodying wherein such at least one metalsurface portion comprises a plurality of non-porous strut portionsstructured and arranged to add stiffness), as shown. Non-perforated band1235 preferably extends from inner diameter to outer diameter of hydridedisk 1210, as shown. Non-perforated band 1235 preferably comprises awidth 1227 of about 2¾ mm, as shown. Structural integrity maintainer1230 preferably comprises at least one non-perforated inner ring 1240and at least one non-perforated outer ring 1245, as shown.Non-perforated inner ring 1240 preferably comprises a radial width 1242,as shown, of about 2 mm. Non-perforated outer ring 1245 preferablycomprises a radial width 1247 of about 1 mm. Non-perforated band 1235,non-perforated inner ring 1240, and non-perforated outer ring 1245preferably comprise no perforations 1225. Non-perforated inner ring 1240and non-perforated outer ring 1245 are preferably concentric with thecenter of hydride disk 1210. Upon reading this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances considering such issues as future technology, cost,materials, etc. other structural integrity geometries, such as, forexample, greater than three concentric rings, radially-staggered bands,parallel bands, etc., may suffice.

FIG. 13 shows an enlarged sectional view of section 13-13 of FIG. 12B.

Perforations 1225 preferably penetrate completely through hydride disk1210, as shown. Upon reading this specification, those skilled in theart will now appreciate that, under appropriate circumstancesconsidering such issues as future technology, cost, materials, etc.other penetration depths, such as, for example, about half way through,varying depths, etc., may suffice.

Perforations 1225 are preferably angled at about 45° (angle θ, as shown)from perpendicular to surface 1250 of hydride disk 1210, as shown (thisarrangement at least herein embodying wherein such at least one patternof cavities comprises at least one angle, with respect to such at leastone metal surface portion, of about 45°). Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances considering such issues as future technology,cost, laser incidence, etc. other perforation angles may suffice.

Perforations 1225 are preferably linear, as shown. Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances considering such issues as future technology,cost, materials, etc. other perforation geometries, such as, forexample, helical, spiral, elbowed, etc., may suffice.

Perforations 1225 (at least herein embodying wherein such at least onemetal surface portion comprises at least one pattern of cavitiesstructured and arranged to provide substantially uniform porosity)preferably comprise a circular cross-section perpendicular to thecentral axis. Upon reading this specification, those skilled in the artwill now appreciate that, under appropriate circumstances consideringsuch issues as future technology, cost, laser incidence, etc. otherperforation cross-sections, such as, for example, ovular, hexagonal,slit, etc., may suffice.

Hydride disk 1210 preferably further comprises catalyst particles 1255embedded near surface 1250, as shown. Catalyst particles 1255 preferablycomprise nickel, and preferably palladium. Catalyst particles 1255preferably each comprise at least one near-atomic size. Upon readingthis specification, those skilled in the art will now appreciate that,under appropriate circumstances considering such issues as futuretechnology, cost, materials, etc. other catalysts, such as, for example,magnesium, carbon, plastics, etc., may suffice.

Hydride disk 1210 additionally preferably comprises at least one coating1260, as shown. Coating 1260 preferably comprises interspersed Ni andstoichiometric Mg₂Ni. Eutectic compounds formed at surface 1250 betweencoating 1260, catalyst particles 1255 and magnesium in hydride disk 1210preferably prevent separation of coating 1260 (at least herein embodyingwherein such at least one metal surface portion comprises at least onethin surface-coating comprising substantially nickel and Mg₂Ni) fromhydride disk 1210. Upon reading this specification, those skilled in theart will now appreciate that, under appropriate circumstancesconsidering such issues as future technology, cost, materials, etc.other coatings, such as, for example, pure Mg₂Ni, pure nickel, plastics,cermets, etc., may suffice.

FIG. 14 shows a diagrammatic view, illustrating the atomic order ofhydride disk 1210, according to embodiment 1200 of FIG. 13. Hydride disk1210 preferably comprises multiple layers 1265 of hydrogen-storingmaterial 1270, preferably magnesium 1272, as shown. Hydrogen-storingmaterial 1270 preferably comprises at least one crystalline structure1275, as shown. Within crystalline structure 1275, hydrogen-storingmaterial 1270 preferably stores hydrogen 1280, as shown.

FIG. 15 shows a flow chart, illustrating at least one hydride diskmanufacturing process 1500, according to the preferred embodiment ofFIG. 14. Hydride disk manufacturing process 1500 preferably comprisesthe steps of: precipitating sheet 1510; cutting disks 1520; perforatingdisks 1530; etching disks 1540; washing disks 1550; embedding catalysts1560; and coating disks 1570. During hydride disk manufacturing process1500, materials used and processes conducted are preferably kept in aninert atmosphere, alternately preferably under vacuum.

In step precipitating sheet 1510 (at least embodying hereinprecipitating at least one hydrogen storer material adapted to storehydrogen), at least one sheet 1410 of hydrogen-storing material 1270 ispreferably precipitated using precipitation technique 1610, as shown inFIG. 16. Sheet 1410 preferably comprises about 99% by wt magnesium,preferably with a thickness of about 0.6 mm. Sheet 1410 is preferablyfabricated with the addition of metals designed to provide enhancedstrength, reduced reflectivity, and greater amalgamation when hydrated.Sheet 1410 preferably comprises magnesium, nickel, lithium, boron,aluminum, copper, zinc, and iron, in weight ratios as listed in Table 1.

TABLE 1 Constituents of Specialty Mg Sheet Constituent by Wt % Magnesium99.95 Nickel 0.020≧≦0.025 Lithium* 0.005≧≦0.010 Boron* 0.005≧≦0.010Aluminum ≦0.005 Copper ≦0.005 Zinc ≦0.001 Iron ≦0.001

In step cutting disks 1520 (at least embodying herein cutting such atleast one hydrogen storer material into at least one geometric shape),sheet 1410 (at least herein embodying wherein such at least one metalsurface portion comprises precipitated magnesium plate adapted to be cutinto disks and contain such holes) is preferably cut into at least onedisk 1420, as shown, comprising a diameter of about 120 mm and a centerhole 360 of about 15 mm diameter. Dimensions of disk 1420 are preferablyhorizontally similar to conventional compact disks which were introducedas removable storage medium (CD-R) in 1988. Upon reading thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances, considering such issues as futuretechnologies, costs, materials, etc., other disk manufacturingprocesses, such as, for example, directly precipitating disks,precipitating cylinders, etc., may suffice.

In step perforating disks 1530 (at least embodying herein perforatingsuch at least one hydrogen storer material), disk 1420 is preferablyperforated, preferably with greater than 500,000 perforations 1225,preferably forming at least one perforated disk 1430. At least oneperforating process 1700 is discussed in connection with FIG. 17.

In step etching disks 1540 (at least embodying herein etching at leastone surface of such at least one hydrogen storer material with at leastone chemical), perforated disk 1430 is preferably briefly exposed tohydrochloric gas 1545, preferably between about 40% and about 50%concentration, preferably to provide a sub-micron surface texture. Suchexposure to hydrochloric gas is preferably conducted at a temperature ofabout 70° C., preferably at about 2 psi, preferably for about 15seconds. Step etching disks 1540 preferably produces at least one etchedperforated disk 1440.

Following step etching disks 1540, etched perforated disk 1440 ispreferably then placed in an inert atmosphere low pressure sandblaster.In step washing disks 1550 (at least embodying herein washing such atleast one surface to remove such at least one chemical), etchedperforated disk 1440 is preferably spun on a plate preferably placedabout 25 mm from a series of circularly placed nitrogen gas nozzles 1553married to separate vacuum feed and vacuum removal systems. etchedperforated disk 1440 is preferably “washed” with <500 mesh about 99.95%atomized magnesium powder 1555 preferably under weak pressure ofNitrogen gas (about 99.999% purity) to preferably ensure no residualchlorine or MgCl₂ is left on etched perforated disk 1440, and preferablyonly trace amounts (<100 ppm) of Mg(NH₃)₆Cl₂ can be detected. Stepwashing disks 1550 preferably results in at least one washed disk 1450.

In step embedding catalysts 1560 (at least embodying herein embedding,in such at least one surface, at least one catalyst structured andarranged to assist hydrogenation of such at least one surface), nitrogengas is then used to deliver catalyst particles 1255, preferablyprecipitated and atomized nickel (99.999+%) and palladium (99.99+%)powders, (at <500 mesh) to washed disk 1450. Delivery of catalystparticles 1255 is preferably conducted at between about 5 psi and about15 psi for periods ranging from about 5 seconds to about 10 seconds.Overspray preferably nets a resultant exposure of about 0.05 seconds persquare mm to catalyst particles 1255. Steps washing disks 1550 andembedding catalysts 1560 preferably provide the necessary catalystparticles 1255, through simple impact adhesion, to act as catalystelements, preferably without significant ablation of magnesium inresulting catalyzed disk 1460 or reduction of the surface area createdin step etching disks 1540. The impact of magnesium, nickel, andpalladium powder preferably creates sub-micron fractures in the surfaceof catalyzed disk 1460 and preferably provides embedded particles(catalyst particles 1255) to preferably act as precipitation points forre-nucleation of magnesium when dehydrogenating from MgH₂.

In step coating disks 1570 (at least herein embodying coating such atleast one surface with at least one surface reaction preventer), coating1260 is preferably applied to catalyzed disk 1460. Nickel carbonyl andmagnesium are preferably decomposed, preferably by sublimation,preferably in separate decomposition reactors 1575 resulting in gaseousnickel 1573 and gaseous magnesium 1577. Gaseous nickel 1573 and gaseousmagnesium 1577 are preferably fed into reactor 1572. The atoms ofgaseous nickel 1573 and gaseous magnesium 1577 preferably mix with eachother as they preferably precipitate onto catalyzed disk 1460, which ispreferably cooled. This process is repeated with cycles of heating andcooling of the disk. Coating 1260 is preferably created from the vaporsof the impregnated magnesium and the gaseous precipitates. Coating 1260preferably aids in preventing loss of stored hydrogen in storage. Stepcoating disks 1570 utilizes precipitation technique 1610, similar tostep precipitating sheet 1510, using catalyzed disk 1460 asprecipitation stage 1680 (see FIG. 16).

Hydride disk manufacturing process 1500 preferably yields at least onehydrogenation-ready disk 1580. Hydrogenation-ready disk 1580 preferablycomprises about 9.5 grams preferably with an average pre-hydrogenationdensity of greater than 5 g/cubic cm for the surface 2 μm, preferably adensity of greater than 1.8 g/cubic cm from a depth of 2 μm to 20 μmbelow the surface in perforated areas, and 1.74-1.78 g/cubic cm from 20μm to the center 250 μm in areas which are not perforated.

FIG. 16 shows a diagrammatic view, illustrating sheet manufacturingprocess 1600, according to the preferred embodiment of FIG. 15. Sheetmanufacturing process 1600 preferably comprises precipitation technique1610, as shown. In precipitation technique 1610, at least oneconstituent component 1620 is preferably decomposed in at least onedecomposition reaction chamber 1630. Decomposition reaction chamber 1630preferably heats constituent component 1620 while maintaining a vacuum1640. Temperature 1650 and vacuum 1640 preferably comprise at least onecondition in which constituent component 1620 preferably sublimatesforming at least one gaseous constituent component 1660.

Gaseous constituent component 1660 is preferably transferred into atleast one precipitation chamber 1670. Precipitation chamber 1670preferably cools gaseous constituent component 1660, preferably allowinggaseous constituent component 1660 to precipitate onto at least oneprecipitation stage 1680. Precipitation stage 1680 is preferably chilledto at least one precipitation temperature 1690. Precipitation technique1610 preferably allows uniform distribution of multiple constituentcomponents 1660, preferably molecularly layered, to form sheet 1410using constituent components 1660 as listed in Table 1.

Upon reading the specification, those skilled in the art will nowappreciate that, under appropriate circumstances, other sheetmanufacturing processes, such as, for example, sputter precipitation,electrolytic precipitation, other future molecular layering techniques,etc., may suffice.

FIG. 17 shows a diagrammatic view of at least one drilling chamber 1710,illustrating at least one perforating process 1700, according to thepreferred embodiment of FIG. 15.

In perforating process 1700, disk 1420 is preferably placed in a coldinert atmosphere and preferably secured flat on at least one stage 1720,preferably comprising at least one submicron-sensitive 3-dimensionalstage. Stage 1720 is preferably cooled; and drilling chamber 1710preferably is kept under vacuum 1712. At least one pressure plate 1730preferably comprises at least one orifice 1740. Pressure plate 1730preferably covers disk 1420, preferably applying pressure in order toprevent warping during perforating process 1700. Orifice 1740 preferablyexposes a circular surface area of about 0.7 mm in diameter of disk1420. Stage 1720 preferably moves to expose different portions of disk1420 during perforating process 1700.

At least one laser 1750 preferably perforates disk 1420, preferablythrough orifice 1740. Laser 1750 preferably comprises a Niobium-YAGlaser. Laser 1750 preferably is collimated with the ability to focus abeam 1752 of about 45 μm diameter, preferably with a divergence of lessthan 2 percent. Laser 1750 is preferably incident at an about 45 degreeangle to disk 1420. Upon reading the specification, those skilled in theart will now appreciate that, under appropriate circumstances, otherperforating processes, such as, for example, wire drilling, plasmadrilling, etc., may suffice.

At least one drilling sequence places perforations 1225 such that noperforations 1225 are placed within about 1 mm of a previously placedperforation 1225 during any about 1 minute period. At least one vacuum1760 evacuates vaporized magnesium 1770 during perforating process 1700for later reuse in step washing disks 1550. Warping is prevented bypressure plate 1730 and such at least one drilling sequence.

FIG. 18 shows a diagrammatic flow chart, illustrating at least onehydrogenation process 1800, according to the preferred embodiment ofFIG. 15.

Hydrogenation process 1800 preferably comprises placinghydrogenation-ready disks 1580 on at least one threaded spindle 1812between at least one spacer 1110, as shown in step spindle disks 1810.Spacer 1110 preferably is cleaned and heat treated in a vacuum, toremove impurities, prior to use. Hydrogenation-ready disks 1580 aresecured, between spacers 1110, with at least one nut 1113 on at leastone threaded spindle 1812.

Hydrogenation process 1800 preferably employs at least one reactor 1120,preferably capable of temperatures of about 500° C. and preferablypressures in excess of about 65 bar. Hydrogenation process 1800preferably takes place between about 55° C. and about 440° C. andpreferably between about 2 bar and about 30 bar, preferably over periodsranging from about 2 hours to about 6 hours. Since magnesiumapproximates a closed packet crystalline structure, twinning ispossible, and preferably desirable, in an enabled isometricconfiguration to improve hydrogen absorption and desorption kinetics.Therefore, hydrogenation process 1800 preferably uses a slow steppedprocess (temperature staging process 1820), preferably which avoidsannealing as much as possible, and preferably allows equalizeddistribution of hydrogen in hydride disk 1210.

Hydrogenation process 1800 preferably uses bottled ultra-pure (99.999%)hydrogen gas, preferably ALPHAGAZ 2, preferably cooled to near liquidstate (cooled hydrogen 1835). During stage 1823 of temperature stagingprocess 1820, small amounts of cooled hydrogen 1835 are preferablyintroduced by high speed, high pressure injection into reactor 1120. Atleast one injection valve 1837 preferably creates an about 1 μs blast ofcooled hydrogen 1835 preferably about each second for an about 10 secondinterval. The about 10 second interval is preferably repeated about 10times. Repeated introduction of the cold hydrogen preferably createssonic pressure waves as cooled hydrogen 1835 expands supersonicallyinside reactor 1120. The super-sonic waves preferably facilitatecracking of coating 1260, and preferably permit deeper hydrogenationinto hydrogenation-ready disks 1580, and preferably later adsorptionfrom hydride disk 1210.

FIG. 19 shows a chart view illustrating temperature staging process1820, during hydrogenation process 1800, according to the preferredembodiment of FIG. 18.

The temperature in reactor 1120 is preferably increased from about 20°C. slowly, and preferably allowed to reach equilibrium at about 55° C.,about 150° C., and about 300° C. preferably over about 1 hour, in stage1821. Stage 1821 comprises a constant hydrogen pressure of about 2 bar.In stage 1822, temperature is preferably then reduced to about 55° C.and pressure is preferably increased to about 30 bar. Temperature ispreferably then increased and preferably allowed to reach equilibriumagain at about 55° C., about 150° C., and about 300° C. preferably overabout 1 hour. Stage 1822 also comprises a constant pressure of about 30bar, preferably utilizing venting as temperature increases. Temperatureis preferably then allowed to rise to about 440° C., preferably movingparticularly quickly between about 350° C. and about 430° C. to reduceannealing.

In stage 1823, reactor 1120 preferably remains at about 440° C.temperature for about 1 additional hour before being cooled. In stage1824, preferably while under constant hydrogen pressure of about 30 bar,reactor 1120 is preferably cooled to about 135° C. Pressure ispreferably reduced to about 2 bar of hydrogen and hydride disks 1210preferably cool further to about 55° C. preferably under a constantpressure of about 2 bar, in stage 1825. Hydride disks 1210 arepreferably then removed to at least one inert gas oven at about 55° C.and about 1-2 bar, to undergo stage 1826. Hydride disks 1210 arepreferably then cooled as the oven temperature reduces and inert gas ispreferably added to ensure constant positive atmospheric pressure ofabout 1-2 bar.

FIG. 20 shows a perspective view, illustrating spacer 1110, according tothe preferred embodiment of FIG. 18. Spacer 1110 preferably comprises athickness of about 3 mm. Spacer 1110 preferably comprises at least oneventilator 1115, preferably designed to allow hydrogen flow to as muchsurface area of hydrogenation-ready disk 1580 as possible. Spacer 1110preferably prevents warping of hydrogenation-ready disk 1580 duringhydrogenation process 1800. Spacer 1110 preferably comprises titanium,preferably 99.98% titanium. Spacer 1110 preferably comprises an outerdiameter 1112 of about 130 mm, preferably extending beyond outerdiameter 1214 of hydrogenation-ready disk 1580 to account for expansionduring hydrogenation process 1800.

Upon reading the teachings of this specification, those skilled in theart will now appreciate that, under appropriate circumstances,considering such issues as cost, future technologies, etc., otherhydrogenation methods, such as, for example, laser-induced plasmaionization hydrogenation, thermal heating hydrogenation using chemical,physical or laser cooling of the medium, switched multi-frequency lightactivation hydrogenation, etc., may suffice.

FIG. 21A shows a plan view illustrating at least one hydride disk 1910according to a preferred embodiment of the present invention.

FIG. 21B shows a magnified view of hydride disk 1910 according to thepreferred embodiment of FIG. 21A.

FIG. 22 shows an enlarged view of section 22-22 of FIG. 21B.

Referring to FIG. 21A, FIG. 21B and FIG. 22, an alternative method ofdisk fabrication preferably includes precipitation of constituentcomponents 1620 (as in precipitation technique 1610) onto at least onecore disk 1930 preferably comprising a thickness 1932 of about 0.1 mm.Core disk 1930 preferably comprises carbon, preferably carbon fiber.Core disk 1930 (at least herein embodying wherein such at least onemetal surface portion comprises at least one thin, stiff non-magnesiumframe structured and arranged to add stiffness) preferably providesstability to hydride disk 1910, to replace non-perforated band 1235 asstructural integrity maintainer 1230.

Core disk 1930 preferably comprises hydrogen passages 1920 which arepreferably closed at the top. Hydrogen passages 1920 preferably risefrom core disk 1930 about 0.2 mm, preferably at an angle θ of about 45°.Hydrogen passage 1920 comprises a diameter of about 0.0001 mm (100nanometers), and preferably are perforated to allow passage of hydrogenbetween hydrogen passage 1920 and hydride disk 1910.

Precipitation preferably produces at least one layer 1940 of constituentcomponents 1620 to a thickness 1922 of about 0.2 mm on each side of coredisk 1930. After precipitation hydrogen passages 1920 are preferablysanded opened to reveal holes similar to perforations 1225 and providingthe possibility of more than 5 million hydrogen passages 1920 perhydride disk 1910, which increases surface area and Hydrogen adsorption,without reducing strength or storage capacity.

FIG. 23 shows an enlarged view of section 22-22 of FIG. 21B according toan alternately preferred embodiment of the present invention.

Although most features of embodiment 1300 are repeated from preferredembodiment 1200, in embodiment 1300, as shown, embodiment 1300preferably comprises hydride disk 1310, as shown. Hydride disk 1310preferably comprises at least one magnesium layer 1320 and at least oneNitinol (TiNi) layer 1325. Like in hydride disk 1210, hydride disk 1310preferably comprises perforations 1225, however in hydride disk 1310,multiple perforations 1225 are preferably spaced about 100 μm apart(measured center-to-center).

Magnesium layer 1320 preferably comprises at least one magnesium andnickel formula, in the form of small-grain, semi-porous, deposited andperforated material, preferably formed and preferably perforated in ananaerobic environment (≦50 ppm oxygen) with the 99.99% purityconstituents (Table 2) listed below.

TABLE 2 Constituents of Specialty Mg layer Element Min wt % Max wt %Moles/100 g Purpose Magnesium 98.45 98.55 4.0451 H₂ storage α, β, γNickel 1.45  1.55 0.0256 H₂ storage/kinetics/ elect-opt α, β Oxygen 0.00≦50 ppm 0.0 contaminant/ lowers storage

Nitinol (TiNi) layer 1325 preferably comprises at least one substrateemployed for vapor deposition of Magnesium layer 1320. Nitinol (TiNi)layer 1325 preferably is baked to allow super-elasticity prior to vapordeposition. The vapor deposited (electron beam) magnesium and nickelmaterial grain sizes are preferably similar to those achieved with equalchannel angular pressing at temperatures, which preferably permithomogenous and bimodal grain structures preferably with nano-grains anda small volume fraction of micro-grains. Material grain sizes arepreferably in the range of about 0.4 μm to about 1.1 μm, preferably witha mean value of the planar grain size of less than about 500 nm, withtwins included as grain boundaries. Nitinol (TiNi) layer 1325 preferablyprovides super-elasticity to the deposited material and allows Hydridedisk 1310 to return to the required shape repeatedly after hydrogenabsorption and desorption cycles.

Magnesium layer 1320 preferably comprises structures of stacked partialglancing angle vapor deposition solid sheet magnesium and nickel,preferably with a small grain size (<500 nm diameter), preferably withmicro-fractures which preferably localizes material of nano-clusterspreferably with only about 2500 nm between fractures, and preferablybeam channeling microstructures (50 μm diameter perforations 1225),preferably deposited on Nitinol (TiNi) layer 1325. Preferably, Multi-gunplasma magnetron sputtering, alternately preferably, plasma enhancedmagnetron sputtering (PEMS), alternately preferably, ion-beam assisteddeposition (IBAD), alternately preferably, e-beam evaporation (EVAP) maybe used to create Magnesium layer 1320. Magnesium layer 1320 preferablycomprises suitable semi-porosity, preferably micro-fractures, preferablysolidity, and preferably adequate surface area to effect laser-induceddesorption. Alternately preferably, hydride chemical vapor deposition(HCVD) may be used with a formula which includes hydrogen and preferablyresults in mixtures of MgH₂ and Mg₂NiH₄.

Light beam channeling microstructures (perforations 1225) are preferablyplaced in the material with a focused laser beam preferably in atrepanning manner, alternately preferably in a compounding manner.Perforations 1225 are placed about 100 μm on center apart, and arepreferably created at about a 45 degree angle to the surface.Perforations 1225 may preferably be drilled blind (not through Nitinol(TiNi) layer 1325) when only a single layer of material (thin foil) isto be used. Note that normally layers will preferably be stacked, asshown, and blind holes will not be used.

The storage structure of hydride disk 1310 is preferably porous andpreferably has channels to allow hydrogen and light into, and out of,the material. The fabrication process preferably provides perforations1225 at about a 45 degree angle to the surface, with a preferreddiameter of about 50 μm prior to hydrogen absorption. Perforations 1225will shrink due to expansion during hydrogen absorption. While theoverall material volume change is on the order of 8 to 15%, the holestend to close by more than 20% and have a diameter of about 36 μm afterhydrogen absorption. The channels preferably have an average populationdensity between about 300 and about 440 channels per 0.01 cm2. Theinternal porosity preferably contains about 1000 macro and meso-pores(open cell) per inch. Fabrication is preferably conducted in ananaerobic atmosphere. Initial hydrogen absorption and degassing, withmedium vacuum, preferably will rupture any closed cell structures.

Applicant has found through testing that this preferred formula(Mg+MgNi) and preferred structure (NiTi—Mg+MgNi—NiTi) absorb hydrogen atmodest temperature and hydrogen pressure. What Applicant found to beremarkable and novel is the effect that UV (100 nm to 400 nm) and IRlaser light (400 nm to 1 mm) have on the sorption kinetics of thematerial. The dielectric created by the hydrogen material (MgH2+Mg2NiH4)(higher insulation), while stacked between layers of a partiallyhydrogenated Nitinol (NiTi) metal material (lower insulation) createsmulti-layers of surface plasmon polaritons. The interface between thelayers gives rise to coupled modes in the metal-insulator-metalheterostructure. The ability to control wave vectors through thesestructures can preferably be attained with geometry, including the holesdrilled in the material, and also preferably with triangular V-groovesin the surfaces of the Nitinol metal. The localized surface plasmons inthe metal nano-particles and near the insulator nano-particles, allowselectromagnetic energy to be confined into a volume less than thediffraction limit. This leads to field enhancement and supports emissiveprocesses which further the effect of the UV and laser light inphoton-molecular interactions. In addition, the preferred structuresselected, and preferred frequencies used, preferably allow coupling ofthe electromagnetic field to lattice vibrations at infrared frequencies,and preferably give rise to localized and propagating surface phononpolaritons. This preferred arrangement preferably provides thatphotonics with phonons at infrared frequencies and plasmonics at lowerfrequencies preferably provide sub-wavelength energy localization,preferably with evanescent waves, and together preferably contribute tothe enhanced sorption kinetics observed by Applicant in themagnesium-hydrogen complexes and structures developed with drilledbeam-channel holes, as described herein, and also with triangularV-grooves. Upon reading the teachings of this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances, considering such issues as cost, future technologies,etc., other substrates, such as, for example, silicon substrates, othernickel substrates, gold substrates, iron substrates, etc., may suffice.

Upon reading the teachings of this specification, those skilled in theart will now appreciate that, under appropriate circumstances,considering such issues as cost, future technologies, etc., other lightsources, such as, for example, UV LED, deuterium lamp, laserirradiation, IR electromagnetic energy, diode, diode pumped lasers,active gain media fiber lasers including ytterbium at 1080 nm,multi-wavelength (stable single-, dual- and triple-wavelengthdissipative soliton) in a dispersion fiber laser passively mode-lockedwith a semiconductor saturable absorber with active mode locking(SESAM), etc., may suffice.

These preferred nano-optic and plasmonic effects, in combination withthe previously claimed beam channeling, electromagnetic, andelectro-optical properties, provides insight into the exceptionalexcitation energies noted in release of hydrogen, from preferredformulated and structured metal hydrides, by electromagneticirradiation.

FIG. 24 shows a diagrammatic view of at least one filtered cathodic arcdeposition apparatus 2010 according to an alternately preferredembodiment of the present invention. Material manufacturing method 2000preferably uses filtered cathodic arc deposition apparatus 2010.

Material manufacturing method 2000 preferably is used to produce hydridedisks 1310, for use in hydrogen energy system 100. Materialmanufacturing method 2000 preferably comprises plasma-assisted processesto produce hydride disks 1310. Such plasma-assisted processes preferablycreate the addition of micro-structures similar to those previouslymentioned. Preferred hydride disks 1310, fabricated with the preferredconstituents previously mentioned (see Table 1), are demonstrated tohave the preferred capacity for hydrogen storage, when preferablyfabricated by such plasma-assisted processes.

Material manufacturing method 2000 preferably fabricates hydride disks1310 with layered constituents preferably comprising primarilymagnesium, alternately preferably magnesium and nickel (Table 1),preferably between nickel-titanium (Nitinol) layers to a thicknessbetween 0.06 micrometers and 0.6 mm. While various steps of materialmanufacturing method 2000 are ordinarily uncommon in magnesiumdeposition, they are useful as preferred fabrication steps of thepreferred hydrogen storage material described in this application.Specifically, magnetron sputtering techniques, including ion-beamsputtering, are preferably used for the non-hydrogen containing materialfabrication, and reactive sputtering techniques are preferably used inthe fabrication of hydrogen containing material fabrication. Thehydrogen containing material is nearly identical in composition andstructure to the non-hydrogen containing material with the differencethat the hydrogen is preferably added to the material duringfabrication, rather than as a separate reactor-based process. Theseprocesses preferably allow small grain sizes of magnesium and nickel andpreferably permit absorption and desorption of hydrogen with lightirradiation.

In addition, filtered cathodic arc vapor deposition of the primarilymagnesium and magnesium and nickel constituents, both with and withouthydrogen present in the fabrication process, is alternately preferably auseful method employed for fabricating the preferred hydrogen storagematerial.

The cathodic arc vapor deposition technique is primarily employed in theformation of coatings or films for use in tribological applications,such as the formation of wear-resistant coatings for cutting tools,bearings, gears, and the like. These wear-resistant coatings have beenmade from plasmas formed from titanium or graphite sources. When atitanium source material is used, a reactive gas such as nitrogen isoften introduced into the deposition chamber during the vaporization ofthe titanium source. The nitrogen gas reacts with the titanium, and thecoating plasma within the chamber comprises Ti, N.sub.2 and TiN. The TiNforms a coating that has been found to be a very durable coating. Agraphite source material is used to form diamond-like carbon (DLC)films, tetrahedral amorphous carbon (ta-C), and carbon nitrogen (C:N)films. —reference U.S. Pat. No. 6,100,628 and other descriptions can befound in U.S. Pat. No. 3,393,179 to Sablev, et al., U.S. Pat. No.4,485,759 to Brandolf, U.S. Pat. No. 4,448,799 to Bergman, et al., andU.S. Pat. No. 3,625,848 to Snaper

The use of the cathodic arc vapor deposition technique for magnesium andmagnesium and nickel hydrogen storage material fabrication is novel inat least use to construct a whole material not merely a coating.Important to this preferred process is the preferred ability to createmicro-structures, preferably including columnar micro andnano-structures which preferably permit minimal particle grain size, andpreferably permit desorption of hydrogen with incident photonicirradiation.

A process chamber 2015 preferably holds a deposition substrate 2020where the film-like material is deposited, preferably at least onecathode 2030 that contains the material to be deposited, and preferablyanodes (triggering anode 2045 and process anode 2040) for creating anelectrical potential to preferably vaporize cathode 2030. Depositionsubstrate 2020 is preferably held at a distance of about 25 centimetersalong a line of sight preferably from cathode 2030. Deposition substrate2020 preferably comprising nickel titanium (Nitinol), alternatelypreferably poly(4,4′-oxydiphenylene-pyromellitimide) (Kapton®). Cathode2030 preferably comprises a solid high purity magnesium source,alternately preferably magnesium, to which preferably solid high puritynickel is preferably added, by recessing nickel rods in the magnesium,preferably in amounts to comprise about 2 percent by weight. Uponreading the teachings of this specification, those skilled in the artwill now appreciate that, under appropriate circumstances, consideringsuch issues as future technologies, available materials, cost, etc.,other cathodes, such as, for example, a pressed powder solid cathodes ofmagnesium, a pressed powder solid cathodes of magnesium and nickelpowders, premixed molded magnesium and nickel cathodes, other cathodesof hydrogen storing materials, etc., may suffice.

Process chamber 2015 preferably comprises a portion which is preferablywound with at least one copper coil 2055 to form an electromagnet 2050.Electromagnet 2050 preferably creates an electric field preferably usedduring the deposition of the hydrogen storage material from cathode 2030on to deposition substrate 2020. The field strength preferably comprisesbetween about 0 Tesla to about 0.2 Tesla. A wave controllable voltagesource 2060 is preferably coupled to cathode 2030 (preferably themagnesium and nickel source) to provide an electric arc which preferablyoperates between cathode 2030 and triggering anode 2045 (preferablycomprising tungsten) to vaporize the magnesium or magnesium and nickelfrom cathode 2030, preferably forming plasma. The electric arc ispreferably maintained between the magnesium or magnesium and nickelsource which is preferably electrically biased to serve as cathode 2030,and triggering anode 2045, preferably spaced apart a suitable distanceto initiate the arc of electrical discharge. Process chamber 2015 andprocess anode 2040 attached to deposition substrate 2020 preferably takeover to conduct vaporized magnesium and nickel particles towardsubstrate 2020.

The electric arc preferably carries high electric current levels,preferably from about 25 amperes to about 300 amperes and preferablyvaporizes the magnesium and nickel into a coating plasma. Desiredmicrostructural components of the deposited metal hydrogen storage filmare preferably improved by controlling the movement of the arc over thesurface of the magnesium and nickel source. A suitable magnesium andnickel hydrogen storage film is preferably formed by controlling: themagnetic field generated by electromagnet 2050 of process chamber 2015;the distance between cathode 2030 and deposition substrate 2020; thethermal velocity imparted to the plasma during vaporization; and theelectrical potential difference between deposition substrate 2020 andcathode 2030. Deposition substrate 2020 is preferably held at a negativevoltage preferably within a range of about 0 volts to about 1000 volts.

At least one negative biasing controller 2065 preferably provides atleast one negative bias to deposition substrate 2020. Whennon-conductive substrates and/or non-conductive deposition materials areused, negative biasing controller 2065 preferably comprises at least oneradio frequency voltage source. Metal hydrogen storage films arepreferably deposited on nickel titanium foil and Kapton® film. Thedeposition on these non-conductive substrates requires such at least oneradio frequency voltage source preferably operably coupled to thesubstrate to provide it with a negatively biased voltage. Such at leastone radio frequency voltage source is also required when hydrogen isadded to the material during deposition, as the deposition material(magnesium hydride and magnesium nickel hydride) then is non-conductive.When using conducting substrates, such as silicon or stainless steel,and depositing only conductive deposition materials, such as metal film(without hydrogen), negative biasing controller 2065 preferablycomprises at least one DC bias source, alternately preferably at leastone low frequency pulsed power source (up to 100 kHz). Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as cost, available materials, future technologies, etc., othernegative biasing controllers, such as, for example, grounds, other DCsources, other frequency sources, etc., may suffice.

Material manufacturing method 2000, comprising filtered cathodic arcdeposition method, of preparing the magnesium hydrogen storage materialis preferably performed in a relative vacuum with a base pressurebetween about 0.0000005 Torr (5×10-7 Torr) and about 0.00001 Torr(1×10-5 Torr). Higher pressures between about 0.0001 Torr and about 0.5Torr preferably result when the material is processed to containhydrogen during the deposition process. The pressure rise results fromthe introduction of hydrogen and argon gases to stabilize the electricarc and to preferably incorporate hydrogen into the deposition materialas magnesium hydride and magnesium nickel hydride. Applicant has foundthat the resulting film thickness is similar, as preferred, topreviously described physical vapor depositions of magnesium and nickelfilm performed with ion-beam sputtering and reactive sputteringmentioned, and that using the filtered cathodic arc deposition methodprovides particularly useful results for hydrogen storage within therange of about 0.05 micrometers and about 20 micrometers. The depositedmaterial contains grain sizes similar to those achieved with physicalvapor deposition with sputtering in the range of about 18 nm to about225 nm. The deposited material with grain sizes greater than about 150nm are preferably created with hydrogen added during the fabricationprocess and reflect the higher partial pressure created by addition ofhydrogen to process chamber 2015. The smaller grain sizes reflect loweroperating pressures capable without the addition of gas during thefabrication process. Deposited material preferably forms into a unifiedmaterial, and is preferably manipulatable as a unit. Further, due to thegranular deposition of material, such unified material comprises aunified matrix of granular material. Such unified matrix permits use asa hydrogen storage medium that is a whole solid and not subject to thelimitations of liquids and powders.

After completing the filtered cathodic arc deposition method to create ahydrogen storage material, hydrogen storage material is furtherprocessed to create hydride disks 1310. The hydrogen storage materialmay preferably comprise a homogeneous layer of material, alternatelypreferably alternating layers of Mg+Ni and NiTi, as previouslydiscussed. Additionally, the hydrogen storage material is preferablylaser drilled at a 45 degree angle, as previously discussed (see atleast FIG. 23), to permit light transmission through the stacked layersfor greater hydrogen storage capacity and interaction with laser light.

Example 1

Referring to FIG. 24, there is depicted a schematic representation offiltered cathodic arc deposition apparatus 2010 suitable for performingthe preferred steps of material manufacturing method 2000 for forming aprimarily magnesium and magnesium and nickel hydrogen storage materialpreferably resulting with preferred grain sizes and micro andnano-structures. Such hydrogen storage material preferably is capable ofabsorbing hydrogen and desorbing hydrogen preferably by excitation withphotonic irradiation, as described in this application. Filteredcathodic arc deposition apparatus 2010 is preferably configured andoperated so as to produce magnesium and magnesium nickel films,preferably in a vacuum of about 0.0000005 Torr (5×10-7 Torr). Suchmagnesium and magnesium nickel films preferably comprise a thicknessbetween about 15 microns and about 20 microns. Additionally suchmagnesium and magnesium nickel films preferably comprise grain sizesless than about 150 nm, preferably with an average near about 50 nm.Process chamber 2015 of filtered cathodic arc deposition apparatus 2010is preferably evacuated to a vacuum of about 5×10-7 Torr, preferably byat least one turbomolecular pump 2070 and at least one rotary vane pump2075. Process chamber 2015, substrate holder 2025 and cathode holder2035 are preferably cooled with at least one coolant circulatorsub-system 2080, preferably circulating at least one water and glycolsolution 2085. Substrate holder 2025, coupled to negative biasingcontroller 2065, preferably provides a secondary potential to substrate2020 with a negative potential comprising about −100 volts. Substrate2020 (preferably stainless steel) is preferably placed in contact withsubstrate holder 2025 to provide the indicated negative potential, andis preferably placed about 25 cm above cathode 2030 (preferablymagnesium and nickel). Upon reading the teachings of this specification,those skilled in the art will now appreciate that, under appropriatecircumstances, considering such issues as cost, future materials, futuretechnologies, etc., other substrates, such as, for example, nickeltitanium (Nitinol), Kapton®, nickel foil, silicon, etc., may suffice.

Electrical potential is preferably established between substrate 2020and cathode 2030. Additionally, a magnetic field, comprising about 0.01Tesla, is preferably established with electromagnet 2050, comprisingcopper coils 2055 wound around cathode holder 2035. Wave controllablevoltage source 2060, preferably comprising a first square wave voltagesource with low voltage and high amperage, is preferably operablycoupled to cathode 2030 to provide the electric arc which operates onthe magnesium and nickel source. Triggering anode 2045 preferablycomprises at least one arc-initiating trigger element 2047, preferablycomprising tungsten. Arc-initiating trigger element 2047 is preferablybrought into close proximity with cathode 2030. Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as cost, future technologies, available materials, etc., othertrigger elements, such as, for example, carbon, stainless steel, otherconductive materials, etc., may suffice.

Arc-initiating trigger element 2047 is preferably momentarily contactedto cathode 2030 so that electrical current flows between the electrodes.Arc-initiating trigger element 2047 preferably is then withdrawn and theelectricity arcs between arc-initiating trigger element 2047 and cathode2030. The visible electric arc preferably remains and moves randomlyaround cathode 2030 and vaporizes magnesium and nickel into a plasma asit moves across the surface of cathode 2030, preferably with a deliveredcurrent of between about 25 amperes and about 150 amperes. The vaporizedmagnesium and nickel plasma particles are preferably directed by themagnetic field created by electromagnet 2050 and the electric potentialsbetween substrate 2020 and cathode 2030. The ion energy is preferablyrelative to the ion current and the partial pressure in process chamber2015. The thermal velocities and the electric potentials accelerate themagnesium plasma species with a kinetic energy of about 8 eV in the5×10-7 Torr vacuum chamber with no added partial gas pressure and an arccurrent of about 150 amperes and a substrate potential of about −100volts. The film coating is preferably deposited with a DC bias on theconductive stainless steel substrate and without addition of hydrogengas. The magnesium rich plasma is preferably readily visible throughglass portals in process chamber 2015, not shown, with a bright greenishblue color with spectral peaks at 516.7, 517.3, and 518.4 nm. The filmof magnesium with grain sizes of less than about 150 nm, and mostcommonly about 50 nm is preferably deposited with columnar structuresinduced by magnetic field modulation to a thickness of about 15 micronsto about 20 microns in less than about 2 minutes.

Alternatively, other non-conducting substrates preferably may beutilized, including Kapton® and NiTi with the coupling of aradiofrequency voltage source to the substrate rather than the DC bias,as previously discussed above.

Example 2

Referring to also to FIG. 24, there is depicted a schematicrepresentation of filtered cathodic arc deposition apparatus 2010suitable for performing the preferred steps of material manufacturingmethod 2000 for forming a primarily magnesium hydride and magnesium andnickel hydride hydrogen storage material preferably resulting withpreferred grain sizes and micro and nano-structures. Such hydrogenstorage material preferably is prepared with absorbed hydrogen and iscapable of desorption of hydrogen, therein contained, by excitation withphoton irradiation, as described in this application, and absorbinghydrogen after such desorption. Filtered cathodic arc depositionapparatus 2010 is preferably configured and operated so as to producemagnesium hydride and magnesium hydride plus nickel and nickel hydridefilms in a vacuum with a partial gas pressure of about 0.0005 Torr(5×10-4 Torr). Such magnesium hydride and magnesium hydride plus nickeland nickel hydride films preferably comprise a thickness of betweenabout 20 microns and about 30 microns. Additionally such magnesiumhydride and magnesium hydride plus nickel and nickel hydride filmspreferably comprise grain sizes between about 150 nm and about 400 nm,with an average near about 225 nm. Process chamber 2015 of filteredcathodic arc deposition apparatus 2010 is preferably evacuated to avacuum of about 5×10-7 Torr, preferably by at least one turbomolecularpump 2070 and at least one rotary vane pump 2075. Process chamber 2015,substrate holder 2025 and cathode holder 2035 are preferably cooled withat least one coolant circulator sub-system 2080, preferably circulatingat least one water and glycol solution 2085. Substrate holder 2025,coupled to negative biasing controller 2065, preferably provides asecondary potential to substrate 2020 with a negative potentialcomprising about −100 volts. Substrate 2020 (preferably nickel titanium)is preferably placed in contact with substrate holder 2025 to providethe indicated negative potential, and is preferably placed about 25 cmabove cathode 2030 (preferably magnesium and nickel). Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as cost, future materials, future technologies, etc., othersubstrates, such as, for example, stainless steel, Kapton®, nickel foil,silicon, etc., may suffice.

Electrical potential is preferably established between substrate 2020and cathode 2030. Additionally, a magnetic field, comprising about 0.01Tesla, is preferably established with electromagnet 2050, comprisingcopper coils 2055 wound around cathode holder 2035. Wave controllablevoltage source 2060, preferably comprising a first square wave voltagesource with low voltage and high amperage, is preferably operablycoupled to cathode 2030 to provide the electric arc which operates onthe magnesium and nickel source. A partial pressure of filter-driedultra-high purity hydrogen gas is preferably allowed to enter thechamber while controlled by at least one mass flow controller 2090 untila partial pressure in the chamber has risen to about 1×10-5 Torr.Triggering anode 2045 preferably comprises at least one arc-initiatingtrigger element 2047, preferably comprising tungsten. Arc-initiatingtrigger element 2047 is preferably brought into close proximity withcathode 2030. Upon reading the teachings of this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances, considering such issues as cost, future technologies,available materials, etc., other trigger elements, such as, for example,carbon, stainless steel, other conductive materials, etc., may suffice.

Arc-initiating trigger element 2047 is preferably momentarily contactedto cathode 2030 so that electrical current flows between the electrodes.Arc-initiating trigger element 2047 preferably is then withdrawn and theelectricity arcs between arc-initiating trigger element 2047 and cathode2030. The visible electric arc preferably remains and moves randomlyaround cathode 2030 and vaporizes magnesium and nickel into a plasma asit moves across the surface of cathode 2030, preferably with a deliveredcurrent of between about 25 and about 150 amperes. The vaporizedmagnesium and nickel plasma particles are preferably directed by themagnetic field created by electromagnet 2050 and the electric potentialsbetween substrate 2020 and cathode 2030. The ion energy is preferablyrelative to the ion current and the partial pressure in process chamber2015. The pressure in the chamber is preferably adjusted by the controlof hydrogen gas to a partial pressure between about 1×10-5 Torr andabout 1×10-4 Torr. The thermal velocities and the electric potentialspreferably accelerate the magnesium plasma species with a kinetic energyof about 8 eV, however contact with hydrogen creates hydrogen ions anddegrades the energy of the magnesium. A significant portion of themagnesium ions then preferably combine with hydrogen ions to formmagnesium hydride. The resulting magnesium hydride particles have asignificantly reduced kinetic energy and electrical potential. The useof a high power, high frequency (13.56 MHz) radio frequency voltagesource and impedance matching network preferably assists in thedirection of the plasma and recombined species toward the substrate. Thearc current of 200 amperes and a substrate potential of −150 volts,along with the high power RF voltage source preferably produces amagnesium, magnesium hydride, nickel and nickel hydride film coating onthe non-conductive nickel titanium substrate with grain sizes of about150 nm to about 300 nm, and most commonly about 225 nm, with columnarand angular structures induced by magnetic field modulation anddifferential species potentials to a thickness of about 20 microns toabout 30 microns in about 4 minutes.

Example 1 and Example 2 represent the fabrication of a preferredmagnesium and preferred magnesium plus nickel thin films whichincorporate, as part of the invention, the storage of hydrogen in amaterial which absorbs or contains hydrogen for desorption andadsorption of hydrogen by laser irradiation. These films are preferablystacked, preferably up to 7 layers thick, for increased storage capacityand preferably plasmonic interaction effects between layers, aspreviously discussed. These films are preferably further processed withlaser hole drilling, after stacking, to incorporate light beam channelswhich facilitate hydrogen absorption, desorption, stress relaxation, andlight penetration (see at least FIG. 23). The storage capacity of theselayered materials is preferably similar to other methods of fabricationmentioned previously with a maximum near 5 percent, by weight, hydrogen.

Although applicant has described applicant's preferred embodiments ofthis invention, it will be understood that the broadest scope of thisinvention includes modifications such as diverse shapes, sizes, andmaterials. Such scope is limited only by the below claims as read inconnection with the above specification. Further, many other advantagesof applicant's invention will be apparent to those skilled in the artfrom the above descriptions and the below claims.

What is claimed is:
 1. A hydrogen energy method comprising the steps of:a) using at least one material deposition apparatus structured andarranged to manufacture at least one hydrogen storer; and b)manufacturing such at least one hydrogen storer structured and arrangedto store at least one substantial amount of hydrogen; c) wherein such atleast one hydrogen storer comprises at least one hydrogen-releasepermitter structured and arranged to permit photonic-excitation-assistedrelease of stored hydrogen from such at least one hydrogen storer; andd) providing such at least one hydrogen storer to assist at least oneuse of hydrogen gas.
 2. The hydrogen energy method according to claim 1wherein the step of using at least one material deposition apparatuscomprises the step of using at least one filtered cathodic arcdeposition apparatus.
 3. The hydrogen energy method according to claim 2wherein the step of manufacturing such at least one hydrogen storercomprises the step of forming at least one layer of hydrogen storermaterial.
 4. The hydrogen energy method according to claim 3 whereinsuch hydrogen storer material comprises magnesium.
 5. The hydrogenenergy method according to claim 3 wherein such hydrogen storer materialcomprises magnesium hydride.
 6. The hydrogen energy method according toclaim 3 wherein the step of manufacturing such at least one hydrogenstorer further comprises the step of forming alternating layerscomprising such at least one layer of hydrogen storer material and atleast one layer of Nitinol.
 7. The hydrogen energy method according toclaim 6 wherein such hydrogen storer material comprises magnesium. 8.The hydrogen energy method according to claim 6 wherein such hydrogenstorer material comprises magnesium hydride.
 9. The hydrogen energymethod according to claim 3 wherein the step of forming at least onelayer of hydrogen storer material comprises the step of deposition ofsuch hydrogen storer material on at least one substrate structured andarranged to receive deposition of such hydrogen storer material.
 10. Thehydrogen energy method according to claim 9 wherein such at least onesubstrate comprises stainless steel.
 11. The hydrogen energy methodaccording to claim 10 wherein such hydrogen storer material comprisesmagnesium.
 12. The hydrogen energy method according to claim 9 whereinsuch at least one substrate comprises Nitinol.
 13. The hydrogen energymethod according to claim 12 wherein such hydrogen storer materialcomprises magnesium hydride.
 14. The hydrogen energy method according toclaim 3 wherein the step of forming at least one layer of hydrogenstorer material comprise the step of creating at least one magneticfield encompassing such hydrogen storer material during formation ofsuch at least one layer.
 15. The hydrogen energy method according toclaim 1 wherein such at least one hydrogen storer comprises a thicknessgreater than about 15 microns.
 16. The hydrogen energy method accordingto claim 15 wherein such at least one hydrogen storer comprises athickness between about 15 microns and about 30 microns.
 17. Thehydrogen energy method of claim 1 further comprising the step of formingat least one pattern of cavities structured and arranged to providesubstantially uniform porosity.
 18. The hydrogen energy method accordingto claim 17 wherein said at least one pattern of cavities comprises atleast one angle, with respect to at least one surface of hydrogen storermaterial, of about 45°.
 19. The system according to claim 18 whereineach of said cavities comprises a diameter of about 50 μm.
 20. Thehydrogen energy method according to claim 1 wherein the step ofmanufacturing such at least one hydrogen storer comprises the step offorming such at least one hydrogen storer as a disk.
 21. The hydrogenenergy method according to claim 1 wherein said at least one hydrogenstorer comprises: a) a unified matrix of granules in a materialstructured and arranged to cyclically store hydrogen and release storedhydrogen; and b) wherein controlled storage and release of hydrogen isachieved.
 22. The hydrogen energy method according to claim 21 whereinsaid unified matrix of granules comprises grain sizes less than about300 nm.
 23. The hydrogen energy method according to claim 22 whereinsaid unified matrix of granules comprises grain sizes less than about150 nm.